Carbon Fiber Crazy

[farmerbraun]

This should be good.

So I thought I'd brush up on some skills from the past and avoid paying for custom body work at the same time. I'm not big on the flashy carbon look and hype (tinted clear coat will take care of that).

Here are some pics of the process I'm familiar with:

For the buck I chose to use florist foam. It is extremely easy to shape which also makes it easy to make mistakes

Basic tool like hack saw blade and 60 grit sandpaper make it go smooth. After it's about 98% there I dusted it with black rattle can to get the idea of the finished product.

Next, bondo coat to finalize the buck. Then make the mold.


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[jungalist]

looking very good, sir!

 

[farmerbraun]

Thanx. Just realized while sitting on it for the first test fit that the back corners dig into the thighs. I guess a little more massaging to do.


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[SONICJK]

I'm in to watch.
The whole shebang looks a bit wide though, it may just be the photos.

 

[farmerbraun]

Ya when it digs into the thighs it forced my knees out. Same time though I'm trying to stay in proportion with the wide triple engine.


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[farmerbraun]

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[farmerbraun]

Got a chance to put the tank on diet this weekend.
Before:

After:

Still needs a little time spent on it to get completely symmetrical.


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[mathil]

Are you building a plug right now, with proper molds to come, or are you going to try overlaying with the carbon?

 

[farmerbraun]

These will be the plugs.
Once these foam plugs are as close as possible, ill coat them with bondo to get them as accurate as possible. The bondo will be painted, clear coated and buffed before laying up the molds. Looks like they're going to be split molds too.


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[caferay]

Thanx. Just realized while sitting on it for the first test fit that the back corners dig into the thighs. I guess a little more massaging to do.

The tank or the thighs?

 

[caferay]

Looks like a living room shop. I'm not sure how much CF work you've done, but once you start cutting and sanding with it, you really have to be careful with the particulates, for yourself and anyone else around you. You'll need good dust control and N95 masks. Consider the stuff as bad as asbestos.

http://www.nhs.uk/news/2008/05May/Pages/Cancerriskwithcarbonnanotubes.aspx

 

[SF]

what color carbon you thinkin to use?

 

[dualero]

The tank or the thighs?

I think he meant the rear corners of the tank were touching his thighs when sitting on the bike, making his knees go outside

DH900sl

 

[farmerbraun]

what color carbon you thinkin to use?

It is going to be the more common black 2x2 twill carbon. When its all done I'll be clear coating it with a dark tint in the clear coat.

Yes the tank was what needed massaging. Thighs too but that's not anything to do with the build. lol

 

[farmerbraun]

Looks like a living room shop. I'm not sure how much CF work you've done, but once you start cutting and sanding with it, you really have to be careful with the particulates, for yourself and anyone else around you. You'll need good dust control and N95 masks. Consider the stuff as bad as asbestos.

http://www.nhs.uk/news/2008/05May/Pages/Cancerriskwithcarbonnanotubes.aspx

I have had quite a bit of experience with carbon fiber, but not wet lay. In the past my experience was primarily pre-impregnated carbon and Kevlar. Your right, that is in my house. Believe it or not it was my beautiful wife's idea (lucky me) ;D. All my dirty work is done elsewhere. Carbon dust can really mess up other electronics in the immediate area if you allow that crap to collect. I'll be using a respirator during any cutting and sanding. Thnx