Audi A5 project.


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jaffa
jaffa
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i did a boot for my first attempt including infusion! So don't be shy, I would start with a smaller part first though to limit costs on the first few attempts that go in the bin Smile 
Dravis
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I totally agree on the point of large flat/simple shapes being much easier to do ... but also much more expensive when you get them wrong.. Blink

I started out trying to make very small, rather complex parts, since I had access to small laboratory vac pumps and not much worktop space..  I did not make successful parts for the first 4 - 5 times .. Pinch

I then did some tries "totally simple" and made some medium sized flat panels and very simple "bowl -shapes" (for Sub-woofer -membranes)  This was all wet-lay in the beginning, but with vac-bagging ..  and very successfull .. But you do not learn from doing the easy stuff .. so I started reading and trawling all the composites forums and looking at the *tube -- Cool

Then I went back to the small complex shapes /moulds, and tried again ... with much more success BigGrin

Then I went "skinning" ... And found it quite difficult and a lot more work to get a "shiny" result .. Then I bought a bigger pump and some time later the "infusion kit" from EC .. And that really got me going ..

On top I started experimenting with steel and aluminium moulds -- milled from stock .. and doing what some people call "forged carbon"  for smaller parts .. with varying success ..

I would think that a large bonnet like the one from an Audi A5 is quite a big one to take on as "a first"  -- I would hesitate a bit even WITH my current level of experience to be honest ..

Infusion would be the method of choice, but that process does not get any easier with bigger size ....

My biggest pieces have been bike tank covers and fairing panels .. They were not difficult at all ..  And still I had a few "fails" with parts that had tight corners  .. trapped air .. bubbles, poor cosmetic finish .. bridging --

"Sapere Aude"... Dare to KNOW!

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MarkMK
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To echo the above, the part you're taking on should be relatively straightforward to mould, but just plan carefully and be as neat as you can with your outer edges and give yourself at least 4 inches of flange area all around. Steep transitions from part edge to flange can leave you with areas prone to bridging, so use plenty of wax etc. to smooth this out

I'd recommend using the Unimould system over the epoxy gelcoat/resin option, as it's much more forgiving and easier to make good any areas of imperfection, which you might get on such a large surface area
Hanaldo
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Ronny (15/11/2015)
Isn't this a too big undertaking?
I mean, im new at this to and i ruin moulds, parts i create moulds from and the final part itself.
And i try only small parts.

I know the EC videotutorial looks simple, but it is infact alot of things that needs to be done precisely right.
So if you start on this project be prepared to spend more money on this process then buying a new carbonhood from a supplier.

However getting the hood skinned with carbon on the other hand could be possible for a first timer.


You'll find that small objects are often much more difficult than large ones. A bonnet may be large, but it's nice and flat and very simple to lay up. There's no sharp angles to come unstuck with bridging and voids and other critical issues. Much much easier to make a mould for a bonnet than it is to make a mould for a dash binnacle or something like that. 
davro
davro
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You will be fine!

I would do a few smaller projects first with different moulding systems unimould, epoxy using the smaller kits to get a feel of the materials and tools needed. This will allow you to gauge future project material requirements alot easier.




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VVS
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As a vehicle finisher you will be ok, alot of the techniques used are the same.

you will have no problems preparing the pattern and the mould itself is not hard to do, get the catalyst rates correct and work quickly.

I don't know if its possible to do a part that size using wet lay but to do it correctly you need to infuse so will have the extra expensive of vacuum and consumables be its a nice clean way to work.
djtd
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I am rather good with my hands and a VERY quick learner. I'm a panel beater / refinisher by trade so always working to specifics. 
VVS
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It is actually very difficult and incredibly easy all at the same time.

if you are good with your hands a quick to learn you will succeed, if not you will fail miserably!

watch the EC videos on making a bonnet and then make a honest decision, can you do as the video or not.

you cannot cut corners and need to follow the principles accurately, it can work, ive made parts for my bike so anyone can.

read,read and then read some more.

the uni-mould kit covers .7m so two should do a bonnet.
djtd
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I hear you. I don't expect it to be as simple as it looks lol. 

What is the process of skinning the bonnet? 

I've not seen it done before. 
Ronny
Ronny
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Isn't this a too big undertaking?
I mean, im new at this to and i ruin moulds, parts i create moulds from and the final part itself.
And i try only small parts.

I know the EC videotutorial looks simple, but it is infact alot of things that needs to be done precisely right.
So if you start on this project be prepared to spend more money on this process then buying a new carbonhood from a supplier.

However getting the hood skinned with carbon on the other hand could be possible for a first timer.
GO

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