Dashboard parts


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Inkatreker
Inkatreker
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Hello everybody,
I'm new on this business, so I hope you can help me with this issue.
I want to make some dashboard's parts (23x18x1.5 cm) with carbon fiber laminating kit. However, these parts seem to be a little complicated to make a mould first, and then the carbon fiber part. I think there wouldn't be problem any problem with the front of the part (see picture). 

http://www.talkcomposites.com/Uploads/Images/89dce4c8-afed-4063-97ed-5630.jpg


But I see some difficulties with the back of the part due to flanges, ribs or threads (see picture) where screws make this part fit in the dashboard.

http://www.talkcomposites.com/Uploads/Images/be0381c3-b3bc-499f-8c48-73af.jpg            http://www.talkcomposites.com/Uploads/Images/85090a78-c93f-439a-a8bf-72a1.jpg


I was thinking in making a mould of the front and then make the front with carbon fiber. Then make a mould of the back and then make the back with resin only, since I see a bit difficult to use carbon fiber or glass fiber to make the back. The problem would be to join both parts together and get the right thickness of the original part. Fail to do this will mean noise because of vibration and also part wouldn't fit in dashboard properly.

Do you have any advice to make this part properly? Have you ever made a similar part like this?
Do you know if it's possible to mix carbon fiber and glass fiber in order to get the required thickness?
Do you know the right technique to make this part and similar ones?

I would really appreciate your answers.

Thanks.
Hanaldo
Hanaldo
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The simple answer is that it can't really be done. 

Those parts are made via plastic injection moulding, a technique which is totally different to composite moulding. The only way to do it with composites is to mould the front, and produce that in carbon. Then you need to get creative with your fasteners on the back. I generally use nutserts for threaded fasteners, and fold up some aly flat bar for any tabs etc. Clips and the likes are not your friend, they don't work with composites. The easiest solution is 3M dual lock velcro. 

To be honest, yours looks relatively simple compared to others I have seen. Bond in some nutserts and get some 3M dual lock velcro and you're away. 
Edited 9 Years Ago by Hanaldo
Warren (Staff)
Warren (Staff)
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Realistically skinning using one of our Carbon Fibre Skinning Starter Kits would be the simplest solution.

However you could make a simple moulding to make the outer skin using the laminating kit you have. 

Your question on the brackets is one that we get asked quite a lot an unfortunatelythere isn’t a simple answer to it. When we make carbon fibre parts ourselves weoften wrestle with how we can make replacement parts attach in the same way asthe original ones. The solution is often different every time and sometimesinvolves salvaging some of the clip or bracket off the original part (if it isto be discarded) or making something similar to the original bracket any way wecan (by fashioning it out of a bit of plastic angle for example) or sometimeseven making a small carbon fibre bracket and bonding it to the reverse of theoriginal part. A ‘captive nut’ can sometimes be laminated into the part so thatit can be screwed into.


 In short, there’s no one solution for all. You just need to see whatyou’ve got and do whatever works best each time. Almost always you’ll make thepart without the brackets or fixings and then add them on after. You can bondusing a little of the epoxy resin, a polyurethane resin or something likeAraldite.




Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant
Edited 9 Years Ago by Warren (Staff)
Inkatreker
Inkatreker
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That's a good piece of advice Hanaldo. Thanks.
Any recommendation to stick nutserts, fasteners and tabs to the back of the carbon fiber? I mean, should I use any kind of glue or resin?

Thanks.
Inkatreker
Inkatreker
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Thanks Warren.

Wrapping or skinning was an option too. And probably the easiest one.
If I went for the wrapping option, would it be any way to use a vacuum bagging resin infusion, so I can get a great finish and shape?
VVS
VVS
VVS
posted 9 Years Ago HOT
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If you make the front in carbon you could get some of the release tape, make some wells were the lugs are and use a plastic type metal epoxy to build lugs, ive used devcon to make prototype tools with and it can be machined and tapped,

you would still have to make tabs from say alloy plate but these could be set in the metal epoxy at the same time.
GO

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