Hollow Boot Spoiler


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Shane1985
Shane1985
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Hi guys,

Planning for my first project / business Idea so please and yes I know it will be difficult so please don't shoot me down.

I want to make a CF version of the boot spoiler as pictured below, its hollow and probably about 2-3mm thick.

My question is: is there a way to make a 1 piece mold and then use the resin infusion to make the part?

Or

Does is have to be a split mold using prepreg (or resin infusion?)

Thanks guys

If the pics dont work please see Here


Shane
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*Never give up!*
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Edited 8 Years Ago by Shane1985
kidpaint
kidpaint
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im no expect, but going to say that should be done in a 2 piece mold
kidpaint
kidpaint
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im no expect, but going to say that should be done in a 2 piece mold
Hanaldo
Hanaldo
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It 'can' be done as a single piece, but you're looking at more of a RTM/resin injection process. Definitely not something your average infusion setup will be suitable for. 

The easier method would definitely be pre-preg with an internal pressure bladder. This then requires drilling holes in the piece afterwards to remove the internal bladder. 

The easiest method by far would be to figure out a way to build a joggle into the part, make them in two halves and then bond them together afterwards. This is relatively simple, and I'd recommend doing it on the bottom section of the leading edge for strength reasons. If you build the top section of the mould as per normal, with your split line along the leading and trailing edges, then the second piece of your mould needs to be just a small piece that starts from the split line of the leading edge and extends back about 2 inches onto the bottom of the wing. Then the third piece of the mould can be the remainder. 

Then when it comes time to make the part, you layup the top half with the small piece of the mould so that you can make the leading edge in one piece and don't have a join along that edge. Make the top half first and demould that. Then make the bottom half, and also use the small leading edge piece of the mould but this time apply some sheet wax to it (thickness will depend on how thick your skins are). This will give you your joggle to bond the 2 halves together. 
Shane1985
Shane1985
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Hanaldo - thanks for you write up! its brilliant.

I don't have a clue about joggles and i can only assume you need experience to do it. 

If I was to go the usual route of a 2 piece split mould with the edges of the part being about 2-3mm thick, could I just bond the pieces together?
I can imagine this can be a bit messy but its something i could do, then wet and drying the whole part and finishing with lacquer at my old mans body shop.

I think I am going to need help planning this mould Ermm

Thanks again for your help

Shane


Shane
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*Never give up!*
Hanaldo
Hanaldo
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You can, but honestly it's risky. If you're wanting to sell these parts, then imagine having 30 or 40 of them out there on people's cars for 10 years. The last thing you want is your parts to start falling apart because of a bad bond. 

It's also less consistent and more labour intensive. When you're trying to sell things, you want to be able to pull them out of the mould, trim them up as quick as possible and then do any bonding quickly and easily and know everything is aligned as it should be. With a butt-joint, your trimming becomes quite difficult because if you go too far then you have a big gap but if you don't go far enough then they don't sit together properly. So it's a lot of trial and error that can add up to hours and hours and hours in a production run. Applying the adhesive becomes a task, because you need to keep it off the cosmetic surfaces.

A joggle joint makes the mould a bit more tedious, but from then on everything just works. The parts fit together exactly the same every time, you know where to trim them every time, and your bond will be as strong as the adhesive you are using. 
Shane1985
Shane1985
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Thanks Hanaldo,

I have looked in to Joggle joints and see what you mean, however there are various types.

are you referring to this type?

http://www.talkcomposites.com/Uploads/Images/3c7d10c2-85e8-4d79-b178-9f8a.PNG

Obviously for example of joint only.


Shane
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*Never give up!*
Hanaldo
Hanaldo
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Yeh that's more or less it. It's a lap type joggle joint rather than a tongue and groove type. 

Essentially all you are doing is making an inch of the wing twice, and using the sheet wax to make one slightly recessed so the other one slots over the top of it, both locating the halves together and providing a good amount of surface area for bonding. 

If you really wanted to speed up production you could make the mould, then cover just the small joggle piece in sheet wax before splashing a male plug off it, polish that up and then make another female copy. This will then give you the required joggle for both halves of your complete mould, and you can make both halves at once rather than needing to make the top half and let it cure before you can make the bottom half. 
JustJDee
JustJDee
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Hanaldo you're a genius mate! w00tWow
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