Working with carbon fiber cloth

[JasonSmith]

I'm assuming it is similar to fiberglass cloth to work with. If so, a guy could use his stock part for a mold & just go ape-sh!t nuts with making carbon fiber parts. Right?

[LAKESIDE RESTORATIONS]

Similar, usually it is more costly though. Also being that you are mostlikely going for cosmetics you will want to pay etra attention to making sure it is laying & setting evenly in your mold as well as paying attention to all of the other things that you would normally do in using regular glass layups. Jamie

[Uncle Dave]

Originally Posted by JasonSmith

I'm assuming it is similar to fiberglass cloth to work with. If so, a guy could use his stock part for a mold & just go ape-sh!t nuts with making carbon fiber parts. Right?

Not really-

After laying the carbon cloth directionally in the mold you need another highly expensive item that's also expensive to run-

A combination Autoclave/pressure chamber- large enough to cook all the parts. Mclaren has one of these.

This component is highly expensive to purchase and run.
The parts all need to be skilfully laid up -potentially multiple times with autoclaving in between the layups.

This exposes the carbon fibre to a number of temperature / pressure cycles according to the specific requirements of the materials and components being processed. During this treatment, the resin impregnated in the carbon fibre flows into the surrounding fibres and is activated, thereby curing the carbon fibre. Most of the high stress parts will need an additonal aluminum panel and cloth weave to bond as well- like frame parts for F1 cars.

THIS is why the stuff is brutally expensive.

Uncle Dave

[LAKESIDE RESTORATIONS]

UD is right about it if you are looking to do parts that are not purely cosmetic and that need strength.. Otherwise it wont be too much different than regular glass, just look coooler.

I May have misread the intent of the post.. I thought that it may have just been looking to make something small like a gauge pod or dash panel for cosmetic reasons. Stuff like that.. Sry.. Jamie

[26 Spyder]

I will be fabbing up carbon fiber parts for my Spyder during the reconstruction, I will be posting progress in this section on the Project Wellcraft Restoration thread.
If you need more info I can point you to a few sites with instructional videos.

[glassdave]

Originally Posted by Uncle Dave

Not really-

After laying the carbon cloth directionally in the mold you need another highly expensive item that's also expensive to run-

A combination Autoclave/pressure chamber- large enough to cook all the parts. Mclaren has one of these.

This component is highly expensive to purchase and run.
The parts all need to be skilfully laid up -potentially multiple times with autoclaving in between the layups.

This exposes the carbon fibre to a number of temperature / pressure cycles according to the specific requirements of the materials and components being processed. During this treatment, the resin impregnated in the carbon fibre flows into the surrounding fibres and is activated, thereby curing the carbon fibre. Most of the high stress parts will need an additonal aluminum panel and cloth weave to bond as well- like frame parts for F1 cars.

THIS is why the stuff is brutally expensive.

Uncle Dave

very very true, to gain the benefits of carbon fiber it must be post cured epoxy and autoclaved. cool stuff

But (always a but ) . . . . if its an appearance part you'd like to have there is a method of making a very nice part using polyesters and it is very simple and user friendly. Lets assume you've already made your molds from existing parts, they are seasoned, waxed, polished and ready to go. Its imperative the molds be of the highest surface finish. Spray the mold with clear gelcoat (the type used for glitter flake) and let that kick completely. Using a 5.7 0z 2x2 twill weave carbon fabric lay in a single layer using clear Silmar polyester laminating resin followed by a few layers of 1208 or 1808 Bi-ax depending on how structural of a part you need. Its best to bag this as it is difficult to get an air free layup using conventional methods (although it is possible if you take your time).


couple of tips.

Carbon is tough to lay in a mold without disturbing the pattern of the weave so be careful and try to get it in the first drop. Cut you carbon beforehand and test fit in the dry mold. Be very careful with it and dont get discouraged if you ruin a few. I do it all the time and its all part of tho process.

Silmar kicks quick so go easy on the MEK

Dont bother with black fiberglass that is dyed to mimic carbon. It only looks like it while its still dry and on the roll. Also the dye makes it stiff and you loose most of the drapeability. Once it get wet with the Silmar it becomes opaque black and the detail is pretty much lost.

all the products are available at http://uscomposites.com/products.html

these are some raw out of the mold test pieces (have not been trimmed or buffed) i did of a dash pod i made for a super top secret prototype car/cycle thingie (cant post pics yet)

This is a very easy process and i have been experimenting with some cool layup techniques that, as of yet, have not been done.

[JasonSmith]

Thanks Dave.

[JasonSmith]

Can you shoot a candy color over the resin then clear back over that?
I want to ghost in some stuff on the panels.

[glassdave]

Originally Posted by JasonSmith

Can you shoot a candy color over the resin then clear back over that?
I want to ghost in some stuff on the panels.

sure you can. You can even "window" some graphics like flames or stripes or ??? and have the carbon just show through those areas to give a pretty cool effect. what ever the imagination wants


best advice i can give is that carbon twill weave is very formable but also very sensitive to being disturbed. take your time with the patterns and try to not work it to much when you lay it in the mold.

[cabana1]

glassdave what brand and what type of resin are you using with your carbon fiber? also where do you order from?

thanks
adam