making a carbon fibre intake duct (motorcycle)


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shott92
shott92
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hi im fairly new to making carbon fibre parts and i have been wandering for a while now, how are carbon fibre intake ducts made, i have looked in quite a few places and on this forum but there is no real good answer

the part i am wanting to make is
http://www.pro-fiber.com/shop/published/publicdata/JUUFUENAWASC/attachments/SC/products_pictures/CARBON-AIR-INTAKES-SUZUKI-GSXR-1000-K9-K10j4.JPG

firstly how is the mould or pattern made and secondly what is used carbon braid or carbon sheets and can it be made without an autoclave/oven

could somebody please say what different method there are of making a cast/mould/pattern and what are the pros and cons
what are the pros and cons of the different materials that are available to use
the different methods of laying the CF 
the different methods of curing hardening the part

or could you CF masters at EC make a tutorial video for us thanks

any help would be great thanks very much guys once i have had ago myself i will take pics and let you know how i got on
r0bsk1
r0bsk1
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There are a number of ways you can make these.
1. You can make 2 moulds (upper and lower) and bond the 2 carbon parts together to make the 1 part.
2. Using a 2 part split mould (upper and lower). You then need to compress from the inside of the 2 parts....again theres a couple of ways of doing this
i. Use an internal bladder. Inflate it to increase the pressure and push against the moulds
ii. depending on complexity you could use a solid buck inside. The 2 upper and lower then compress the carbon against it but you risk it crimping on the join.
I have heard that silicone expands when heated but i have no experiance of that myself.

Im trying to make something similar myself for a turbo link pipe for my bike. Its basically a long U shape. Ill be using 2 part mould and an internal bladder. The carbon will be layed up in the 2 halves, clamped together and bladder inflated. The join will not be too visible.

GO

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