I've been making carbon parts for a while and never really had any issues. Most of the issues ive come across ive been able to workout what went wrong and fix it for the next time.
I made moulds for some carbon fibre wing mirrors using the uni mould system as with everything else i make. However with these i cant workout where i am going wrong and how to fix it. I will detail below my layup process and then the issues that i have. The mould is prepared with the usual 6 coats of easylease.
- Due to the shape of the wing mirrors laying in one piece of carbon proved very difficult so i cut two seperate pieces. I need a precise cut on one so i use pro-finish 210g 3k carbon for the front section and then the standard 210g 3k carbon cloth. I do 2 layers of 210g cloth, but for the backing layer, for ease of layup, i cut it into some smaller square sections. These are all laid into the mould using Aerofix 3 spray adhesive. The cloth is cut right upto the edge of the shape of the mirror. I did try overlapping it onto the flange but this just caused more issues with it snapping or cracking trying to get it to release.
- Peel ply - again cut into smaller shapes to conform to the mould and applied with aerofix 3
- bread wrap - I cut this into smaller pieces and hold it in place with a bit of masking tape.
- infusion mesh
- I also leave a resin break
- using IN2 infusion resin which has been degassed
The issues i am facing;
- Can barely get the part to release... sometimes it will crack the carbon around the edge trying to get it out and it has also damaged the surface of the mould, pulling out some of the gelcoat
- pinholes / voids
- the mould is complete mess after each infusion, so much so that i had to resand the whole thing after the first attempt as the flashing round the edge was completly stuck on and its pretty much the same again after the second attempt.
So what should i change? Should i make a split mould instead? Should i slow down the infusion process? Why would the mould surface chip away and be stuck onto the part?
Any help would be much appreciated.