Talk Composites - The Forum for Advanced Composites

Handlebar mould

http://www.talkcomposites.com/Topic17009.aspx

By AlessandroPA - 5/13/2015 11:17:55 PM

Hi all, thanks for your support, if somebody can help me I will appreciate.
I've been asked to make carbon handlebars' prototypes for mountain bikes, something like this
It has to be straight and with a bigger central section of 31,8mm and 22mm on the edges for the grips.
Do you think the high density foam is ok to make the mould? 
In this way, I could make the different sections, connect them, sanding and then wrapping everything with the layers of carbon, to have the right width and sections.  In the end, I could pour acetone in to dissolve the foam and getting the final piece.
The boring detail, is that everytime I need to make a handlebar, I should make again another mould, as it will be one-off.
Except using the technique of two halves connected with bolts (not practical for me, as I make moulds with fiberglass and gelcoat), does anybody know another method to build the mould? 
Thanks Smile

Alessandro 
By AlessandroPA - 5/14/2015 9:16:41 AM

Yes, you are right! I think this is the best solution. The main problem to make the mould is given by the fact the I can't keep off the handlebar finished in one piece

ChrisR (14/05/2015)
sounds like a good plan already, if you make the master part, you could make a 2 part mould from that in silicone then each time you make one you can use expanding foam to make a new inner former