The first step to Carbon Fibre

[scarfacehugo]

Well, I decided to fabricate some Carbon Fiber parts for my RD07 and started to read/watch/ear/eat/sleep every kind of information I could get on the subject.

£200 (in supplies) later, I started to make the mold for my first attempt.

Although the pics make it look quite simple, ther is a lot of work involved, but my guess is, anyone with the shed, patience, hand coordination, organizational skills and money can do it.

Step 1- cover all the open space between the part (to be copied) and the base with plasticine.
Step 2- Wax the part , plasticine and base (wait 2 hours for it to dry)and buff it.
Step 3-Apply PVA (Mold release agent) and wait to dry.
Step 4-First layer of Polyester Gel Coat and wait 1 hour for it to dry.
Step 5- Second layer of Gel Coat and 1 hour to dry
Step 6-First layer of Polyester resin and wait 1/2 hour
Step 7-Fibreglass strand mat
Step 8- Resin, mat, resin, mat, resin, mat (wait 1/2 hour between layers)

Step 9- Wait 12h and release the part from the mold.
Step 10- clean the mold with warm water and soap.

After all this work, you're ready to start laying layers of Carbon cloth...

Stay tuned!

[scarfacehugo]

It is quite impressive to see that the gel coat copies every tiny detail and scratch done to the original part...

[wobblemonster]

Brilliant job that, cant wait for the finished article, its something I have fancied doing myself

[jasonbc]

Brilliant job that, cant wait for the finished article, its something I have fancied doing myself

looks like it's working well and your happy with it. Don't be offended but what is it going to be??

[kitped]

Excellent job, I have always wanted to try carbon fibre. Can't wait to see the final result

[scarfacehugo]

looks like it's working well and your happy with it. Don't be offended but what is it going to be??

I'm not sure if I understood your question, or even if it was directed at me, but the part I'm copying is a XRV750 RDO7 air filter cover.

I'll be able to duplicate this part in CF as many times as I fancy... meaning, soon you'll all be begging me to do so...

[Sohoeasy]

I'm not sure if I understood your question, or even if it was directed at me, but the part I'm copying is a XRV750 RDO7 air filter cover.

I'll be able to duplicate this part in CF as many times as I fancy... meaning, soon you'll all be begging me to do so...

Don't count your chickens just yet. Lets see how many man hours you need to work per unit + materials. These could end up having to sell for £7,500 each ! I hope it goes well though. Ideally you need to mould from factory fresh parts to get the perfik' finish. Fingers crossed

[scarfacehugo]

Don't count your chickens just yet. Lets see how many man hours you need to work per unit + materials. These could end up having to sell for £7,500 each ! I hope it goes well though. Ideally you need to mould from factory fresh parts to get the perfik' finish. Fingers crossed

Yes , you might be right about the labour, but the mould came out pretty perfect, although the part I'm copying is not new. Next week i'll have a prototype.

It's all about the learning process, never about the profit. Boano sell these for 60€...so?

[Sohoeasy]

Yes , you might be right about the labour, but the mould came out pretty perfect, although the part I'm copying is not new. Next week i'll have a prototype.

It's all about the learning process, never about the profit. Boano sell these for 60€...so?

If you could turn up at the ACE overland day in Feb' with several items to sell or promote you could be on to a winner, or at least get back some cash to cover your initial investments.

[japes1275]

The mould looks good. Are you going to vac bag it when you lay up your carbon? I am sort of trained in composites (including CF) but have only limited experience. If you need any tips or information I might be able to help but no guarantees! We only use glass fibre but the priciples are the same.