Hi,

I am after making a carbon/twaron sheet for in the drivers footwell of my car (replacing the majority of the mat).

So my idea is that it will be carbon/twaron by the pedals and then a step down so that some mat will be by the drivers seat.  The step will be created using 3mm closed cell foam.

The drivers mat has got a section that goes up between the foot rest and throttle under the clutch and brake pedal.  I have a piece of carbon fibre that I want to join to a new carbon/twaron sheet, to replicate that piece of mat, but I don't know how I could join the two pieces and get the required angle, which according to my iPhone is 40 degrees.

I want to avoid making moulds if possible.



Can anyone help?

Thanks.

Couple of ways you can do it.

First off, measure the angle as accurately as possible. It doesnt need to be out much to cause a problem as the joint would end up flexing and eventually cracking.

Once you have made the mat, you want to line the two parts up and tape them together. Then using some card board triangles cut to angle, jig the two pieces to the right angle you want.

Turn it over.  Rough up the areas about 2 inch either side of the join line.  Then using some EL2 Epoxy Laminating Resin and some 50mm Carbon Fibre Tape, wet lay the tape over the join until you have built up a bit more thickness than the original carbon mat. 

Once cured, you should have a nice strong join.

The second method is to bend a small piece of alloy sheet to the required angle. Release coat it then wetlay tape as above.  Once cured you have some custom carbon angle you can tidy up then bond to the two carbon sheets to make the carbon mat.


Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

PVA is fine aslong as you get a good even coating.

I would recommend our ET515 Semi Flexible 15min Epoxy Adhesive as it has a high flexural strength so would be more likely to withstand any flexing compared to other adhesives.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant