Westfield parts from a newbie


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Hanaldo
Hanaldo
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Well that's interesting. Have you got any photos? 
Brian2fast
Brian2fast
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I tried taking a couple of pics. In the photographs it doesn't really look like what it is in real life tho. In the pic it looks like bubbles but its definitely not. Its like a milky white colour within the resin and its in areas I know sprayed the glue. 

http://www.talkcomposites.com/Uploads/Images/5acf67c8-7d11-453f-a418-a4ee.JPG


White 'strip' about 45 degrees across middle of pic. This is the worst area but happily all this is covered by the aeroscreen and won't be visible at all.
Hanaldo
Hanaldo
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Ah yep, I see it. Well I guess that confirms the IN2 resin isn't compatible which is both intriguing and unfortunate. I don't have any issues like that with the resin system I am using. I'd be interested to know what causes that. 

This isn't removed with some MEK or a quick polish? 
brainfart
brainfart
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As I said before, make your own spray adhesive by mixing resin and hardener non-stoichometrically (not in the recommended ratio) with a big resin surplus, and dissolve the resulting sticky goo in a suitable solvent. This "semi-hardened glue" has a very long shelf life and since it is basically the same material as the infusion resin it will completely dissolve into and react with the resin during infusion.

As an added bonus, it uses materials you already have, you don't need to order it from obscure sources, doesn't cost you any shipping charges and custom fees and it's A LOT cheaper than any commercial product.
Brian2fast
Brian2fast
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Hi Hanaldo

I tried polishing it out but nope,  its embedded through the resin not just sitting on the top surface. What is MEK?



Hi Brainfart

Yes, I tried your method as well before I did the large part. Maybe it was the spray bottle I used but I ended up with a 'squirt' instead of a fine mist of glue. And then I had to wait for hours before it was tacky. The spray glue was just so easy to use, just spray a little where you needed it wait a few seconds and then you had a really strong adhesive surface rather than just tacky. For a beginner who doesn't have years of experience positioning carbon fabric I just found the can of spray made things so much easier for laying up.

Thanks
Hanaldo
Hanaldo
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MEK is Methyl Ethyl Ketone, it's a type of solvent. Not as aggressive as acetone so better for cleaning cosmetic parts, although it is more dangerous than acetone. Not to be confused with catalyst which is Methyl Ethyl Ketone Peroxide. 

It really is a pity the Aerofix 3 doesn't work so well with the IN2 resin, as you say it makes life so much easier. Hope that stuff that Warren found works for you! 
Brian2fast
Brian2fast
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Hi All

Looking for opinions and advice. My latest part is the nosecone. Before I took a mould off the original I wet sanded the original GRP nosecone to get rid of some light scratches and pitting. But now the mould taken from it does not have the same sharp reflections as the original has. See pics.



Reflections on original nosecone, notice the straight reflections from the strip lights. This was after I wet sanded and machine polished.



Reflections from the mould. Picture was taken the same distance from the surface and at the same time. Reminds me of looking at the tiles at the bottom of a swimming pool! Pish....



Mould and original GRP nosecone.

So what has caused the ripply surface finish on the mould. I used the Unimould system. Followed the same procedure as I always have. Garage was at 20 degrees thorugh out the layup and cure. I use an electric fan heater.

I'm wondering if all my moulds would look like this but its just more noticeable on this due to the larger area on this mould? Or has there been some kind effect from heating when it was curing??

Unless anyone has any other suggestions I think I'm going to wet sand it, 800, 1200 then 1500 grade.

This finish reminds me of a cheap GRP spoiler I fitted to my 205 GTI when I was 19........
Bean Bandit
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I can't help you with your current issue but I must say this is extremly inspireing (just read the whole thread) and I envy all that have such easy acces to quality material products. I got one more business to check next week but I fear their resins are basic cheap stuff - importing DG stuff is very complicated and expensive Sad

Non the less I plan to start this summer experimenting with composites (just started restoring my car from the ground up so it might come in handy Wink )

Best of luck with your future parts and keep posting such great information, much appreciated.
scottracing
scottracing
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The only thing I can think of is that you need to add a bit of bracing to the original nose cone when using it as the plug. I would also have added stiffners like foam lengths to keep the mould more rigid while curing.
Brian2fast
Brian2fast
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Hi All

I thought I was up a certain creak without a paddle last Sunday. I struggled for 10 hours solid trying to demould the carbon nosecone. It was stuck solid. I was even resorting to using a 3 foot crowbar, coil spring compressors used as pullers and one mad attempt with a garden hose.....

I thought I was beat and it was either cut the mould off or cut the carbon out.

Then I spied my kitchen wooden spatula and started using it (after a bit of reshaping) to separate the carbon like a long thin wedge. Today i bought some thin oak and shaved it down to about 3 or 4mm thick by 800mm long, waxed it and then used that to break the last few areas that were stuck in the bottom of the mould.

Pretty happy with the part. No pin holes. Also nice clean reflections after all the hassle with the swimming pool style reflections on the mould surface. This part will save about 1.6kg after I make some carbon mesh to replace the heavy stainless steel mesh I had previous.

http://www.talkcomposites.com/Uploads/Images/19cdd35e-eec3-48f0-926b-acd1.JPG


 Mould with oak 'persuader' wedge.



http://www.talkcomposites.com/Uploads/Images/d0686a9d-e84a-4f45-bb69-19f5.JPG


Part just out the mould. The mesh area was trimmed off while it was still in the mould when i was trying reduce the 'stuck' areas. Pretty risky cos I was using a 4 inch angle grinder but I was getting desperate by then, haha.

http://www.talkcomposites.com/Uploads/Images/2816df06-0d5d-4fec-8a7b-2a33.JPG


Nice even reflections which are the result of about 10 hours wet sanding the mould.....

http://www.talkcomposites.com/Uploads/Images/0a10b011-248d-4373-ae0d-10aa.JPG


Can't really see it cos the pic is too small but the V join turned out good.

Need to trim it up and get it clear coated now.





Craig
GO

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