Best way to lay reinforcement to my complex mould


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baja_patient
baja_patient
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Hi everybody, 

Need some info on laying my reinforcement correctly. 

I am using 2 layers of 200g 2/2 twill cloth and 2 layers of 163g E-glass. 

1) Is it possible to reach all the recesses of the mould using blunt, spatula-like tools with the whole stack on the mould? (very low vac and working gradually?) Can this be done if the top layer is pro-finish carbon?

2) If the above is really not possible without creating any bridges what so ever, can spray tack be used without having a negative effect on the surface of the laminate and the bonding? (I understand EC will be stocking a special spray tack soon, could some info be provided on this)

3) As seen in the picture of the full mould, I will split the reinforcement down the center as this section will be removed later anyway, in order to make the reinforcement more workable. 

4) Alternative methods please, I have seen other carbon body shells in this form so I know it must be possible some how :/

Thanks alot guys. 

http://www.talkcomposites.com/Uploads/Images/59d7aa50-62d1-4470-ba67-06bf.jpg
  
Warren
Warren
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if the mould is big enough, use your fingers to get the cloth into the corners of the mould as you lay up and at every stage.  As long as your nails arent sharp you shouldnt damage anything/burst a bag and you will be able to feel with your fingers far better when youve got the fabric nicely in the corners. You can use blunt tools for tight corners etc but the dexterity and sensitivity of your fingers are usually best if they fit!

Pro finish is "stiffer" than normal carbon, so sometimes it can struggle to get into tight curves where normal fabric would fit in with a bit of distortion.

Regular spray tack will effect surface finish if your not using a gel coat.  It wont cause any release issues on a properly release coated mould.  You could try thinning down some resin with methylated spirits and spritzing it from a little spray bottle as it will help the carbon lay in the mould by slightly wetting it out. Once its infused, you shouldnt have any issues with surface finish like you might get with spray tack.

Cut lines can help you get the fabric where you want. However cut lines will fray so you need to be careful if the cut line is on a visible part of the end product. Pro-finish is good for cut lines as it frays very little compared to normal fabric giving neat cut lines similar in style to what you might see on a pre-preg part.

You could coat the mould in a couple mm thick wax, and cast a silicone "plug" to be pressed into the mould once bagged up to hold the fabric in place and force it into the corners.
fgayford
fgayford
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Warren (18/05/2012)
if the mould is big enough, use your fingers to get the cloth into the corners of the mould as you lay up and at every stage.  As long as your nails arent sharp you shouldnt damage anything/burst a bag and you will be able to feel with your fingers far better when youve got the fabric nicely in the corners. You can use blunt tools for tight corners etc but the dexterity and sensitivity of your fingers are usually best if they fit!

Pro finish is "stiffer" than normal carbon, so sometimes it can struggle to get into tight curves where normal fabric would fit in with a bit of distortion.

Regular spray tack will effect surface finish if your not using a gel coat.  It wont cause any release issues on a properly release coated mould.  You could try thinning down some resin with methylated spirits and spritzing it from a little spray bottle as it will help the carbon lay in the mould by slightly wetting it out. Once its infused, you shouldnt have any issues with surface finish like you might get with spray tack.

Cut lines can help you get the fabric where you want. However cut lines will fray so you need to be careful if the cut line is on a visible part of the end product. Pro-finish is good for cut lines as it frays very little compared to normal fabric giving neat cut lines similar in style to what you might see on a pre-preg part.

You could coat the mould in a couple mm thick wax, and cast a silicone "plug" to be pressed into the mould once bagged up to hold the fabric in place and force it into the corners.


Some guys brush in a layer of epoxy and let it cure to a tacky state and then place the carbon in the mold. Start at the middle pressing the carbon down. The epoxy will grab the carbon because it is tacky. Work your way out to the edges and you are ready to set up for an infusion.

Fred 
GO

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