By antehedis - 11/29/2014 7:38:55 PM
Hello!
Im pretty new to this, but I'ved played around with carbon laminating a while. My next project is to make a carbon saddle for my racebikes.
The saddle is the same as the picture. My question is how to mould this without ruining it. And how do i cover up the stitching and the logo wich is sunk into the "leather", maybe it will do fine wit some filleting wax?
Another question is how i could do the rails (metalpieces underneath) or something similar to them without sanding out a plug. The best would be to just get some mould from them and laminating it, but how do i get them free from air in the process?
/Andreas
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By Dravis - 12/2/2014 10:41:31 AM
This is a much more difficult project to undertake, than it seems, superficially ...
The seat itself gets its properties from the interaction between the steel/alloy "rods" under the seat and the semi-rigid plastic that the leather is bonded to.
If you make a simple mould from the seat upper surface, and lay up a CF "shell" from that, in a thickness that can hold the bodyweight of an adult male (60 - 80 kg) then it will be much stiffer than the original
The two "rods/rails" that make up the "lower suspension" of the saddle are clamped on to the "saddle-pin" in a clamp that relies on high "chrushing forces" from the clamp to hold it in place.
You can not make a CF/resin rod that will stand up to that kind of point load, so you can not make use of the normal saddle-pin you will most likely have to use a specialized saddle pin with longer /wider clamping points.
You should probably take a good long "google-fu" of existing CF saddles ... to sort out how to make it ...
I have tried a fairly long road trip on a racing bike with a CF saddle, and they are extreme to say the least, without very good padding in your cycle shorts, you will discover new worlds of discomfort .. 
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