+x Steve Broad - 7/26/2018 9:41:19 AM+x Fasta - 7/26/2018 8:16:22 AM+x drippy - 7/24/2018 6:30:21 PM+x Fasta - 7/23/2018 3:52:08 PMI have done a similar job to make new carbon boot interior for a Subaru.To do these ones I removed the panels and coated the carpet with a thick type sandable polyester resin and sanded it smooth so that I could mould the new carbon skins directly over the old shapes and release them away after. Then the new parts also needed resin coating etc to get the nice finish. Click To Enlarge Click To EnlargeHow did you get it to keep it's shape when making the mold? Was the resin you used solid enough to keep it's shape? Did it have a form of OEM cardboard that helped?It had some stiffness to begin with and the resin coating just made it stiffer. The parts I made off them were a bit too stiff with 200g carbon cloth, 300g glass cloth and another 200g carbon cloth. In hindsight I might consider just a 165g glass and a 200g carbon. This will keep the new part more flexible so it can flex easy to correct any error in the original mould. To make the parts in this male mould one off technique is a bit of an art compared to a mould but making proper moulds is of course very time consuming and too expensive for the customer.Why are you mixing carbon and fibreglass?https://www.youtube.com/watch?v=j7bQYEt_qtU&t=5s
+x Fasta - 7/26/2018 8:16:22 AM+x drippy - 7/24/2018 6:30:21 PM+x Fasta - 7/23/2018 3:52:08 PMI have done a similar job to make new carbon boot interior for a Subaru.To do these ones I removed the panels and coated the carpet with a thick type sandable polyester resin and sanded it smooth so that I could mould the new carbon skins directly over the old shapes and release them away after. Then the new parts also needed resin coating etc to get the nice finish. Click To Enlarge Click To EnlargeHow did you get it to keep it's shape when making the mold? Was the resin you used solid enough to keep it's shape? Did it have a form of OEM cardboard that helped?It had some stiffness to begin with and the resin coating just made it stiffer. The parts I made off them were a bit too stiff with 200g carbon cloth, 300g glass cloth and another 200g carbon cloth. In hindsight I might consider just a 165g glass and a 200g carbon. This will keep the new part more flexible so it can flex easy to correct any error in the original mould. To make the parts in this male mould one off technique is a bit of an art compared to a mould but making proper moulds is of course very time consuming and too expensive for the customer.
+x drippy - 7/24/2018 6:30:21 PM+x Fasta - 7/23/2018 3:52:08 PMI have done a similar job to make new carbon boot interior for a Subaru.To do these ones I removed the panels and coated the carpet with a thick type sandable polyester resin and sanded it smooth so that I could mould the new carbon skins directly over the old shapes and release them away after. Then the new parts also needed resin coating etc to get the nice finish. Click To Enlarge Click To EnlargeHow did you get it to keep it's shape when making the mold? Was the resin you used solid enough to keep it's shape? Did it have a form of OEM cardboard that helped?
+x Fasta - 7/23/2018 3:52:08 PMI have done a similar job to make new carbon boot interior for a Subaru.To do these ones I removed the panels and coated the carpet with a thick type sandable polyester resin and sanded it smooth so that I could mould the new carbon skins directly over the old shapes and release them away after. Then the new parts also needed resin coating etc to get the nice finish. Click To Enlarge Click To Enlarge
+x Fasta - 7/26/2018 11:56:45 AM+x Steve Broad - 7/26/2018 9:41:19 AM+x Fasta - 7/26/2018 8:16:22 AM+x drippy - 7/24/2018 6:30:21 PM+x Fasta - 7/23/2018 3:52:08 PMI have done a similar job to make new carbon boot interior for a Subaru.To do these ones I removed the panels and coated the carpet with a thick type sandable polyester resin and sanded it smooth so that I could mould the new carbon skins directly over the old shapes and release them away after. Then the new parts also needed resin coating etc to get the nice finish. Click To Enlarge Click To EnlargeHow did you get it to keep it's shape when making the mold? Was the resin you used solid enough to keep it's shape? Did it have a form of OEM cardboard that helped?It had some stiffness to begin with and the resin coating just made it stiffer. The parts I made off them were a bit too stiff with 200g carbon cloth, 300g glass cloth and another 200g carbon cloth. In hindsight I might consider just a 165g glass and a 200g carbon. This will keep the new part more flexible so it can flex easy to correct any error in the original mould. To make the parts in this male mould one off technique is a bit of an art compared to a mould but making proper moulds is of course very time consuming and too expensive for the customer.Why are you mixing carbon and fibreglass?https://www.youtube.com/watch?v=j7bQYEt_qtU&t=5sIn the video he is really only referring to proper loaded structures like an actual race car wing or yacht mast for example. For a car interior part that is just cosmetic there is literally no loads involved and so nothing will ever come near breaking. I am just saving some cost on carbon fibre.Mixing glass and carbon using pre pregs is another story and can create distorted parts different to your moulds.
+x Steve Broad - 7/26/2018 8:24:16 PM+x Fasta - 7/26/2018 11:56:45 AM+x Steve Broad - 7/26/2018 9:41:19 AM+x Fasta - 7/26/2018 8:16:22 AM+x drippy - 7/24/2018 6:30:21 PM+x Fasta - 7/23/2018 3:52:08 PMI have done a similar job to make new carbon boot interior for a Subaru.To do these ones I removed the panels and coated the carpet with a thick type sandable polyester resin and sanded it smooth so that I could mould the new carbon skins directly over the old shapes and release them away after. Then the new parts also needed resin coating etc to get the nice finish. Click To Enlarge Click To EnlargeHow did you get it to keep it's shape when making the mold? Was the resin you used solid enough to keep it's shape? Did it have a form of OEM cardboard that helped?It had some stiffness to begin with and the resin coating just made it stiffer. The parts I made off them were a bit too stiff with 200g carbon cloth, 300g glass cloth and another 200g carbon cloth. In hindsight I might consider just a 165g glass and a 200g carbon. This will keep the new part more flexible so it can flex easy to correct any error in the original mould. To make the parts in this male mould one off technique is a bit of an art compared to a mould but making proper moulds is of course very time consuming and too expensive for the customer.Why are you mixing carbon and fibreglass?https://www.youtube.com/watch?v=j7bQYEt_qtU&t=5sIn the video he is really only referring to proper loaded structures like an actual race car wing or yacht mast for example. For a car interior part that is just cosmetic there is literally no loads involved and so nothing will ever come near breaking. I am just saving some cost on carbon fibre.Mixing glass and carbon using pre pregs is another story and can create distorted parts different to your moulds.Fair comment, but you mentioned using fibreglass to improve it's flexibility. The flexibility is dictated by the carbon, not the fibreglass :-)