learn composites in three easy steps, Race GSXR 400 build (slow)

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*VVS*	*VVS* posted 10 Years Ago HOT Topic Details
Group: Moderators Posts: 226, Visits: 334	First off can i say none of this would happen if it it wasn't for Paul, Matt and the guys at Easy Composites, to say you couldn't meet a nicer, more helpful, informative, interested in your project, etc, etc. bunch of people. Paul and Matt have bent over backwards to help me and thanks have to be said. I first went to EC at the old building to pick up a skinning kit to skin the header tank on my road bike and ended up making a rea rseat cover can be seen in the picture This was a bad idea and has sent me down the road of composite hell, lol I started rebuilding an old gsxr 400 race bike and decided to replace all the old uv damaged panels in CF. first part was the air box so I got to work. will use tank as top of box my first play with wax sheet and filleting wax box fitted to bike Edited 10 Years Ago by VVS
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*VVS*	*VVS* posted 10 Years Ago HOT Post Details
Group: Moderators Posts: 226, Visits: 334	Had to leave the bike sad and lonely for a couple of weeks due to going to Oulton Park and Anglesey for some track time, since getting back I've kicked back in with the moulds and made a couple more. I made the rear hugger, sorry forgot to take photos so will post the infusion. I got the nose cone back out that I'd 3/4 prepared, fitted the up stand to make it a two part mould and got the resin out. Ready for tooling gel coat. First layer of tooling gel coat ready. Glassed up and ready for the other side to be applied, i gave the split a clean with mould cleaner then applied 6 or 7 coats of easy lease. Second side with first layer of tooling gel coat appided. All finished. If anyone wants some advice its don't get greedy and only mix a couple of hundred grams of resin at a time, first pot i mixed was 500 grams and after about 200/250 grams was applied it cooked up in the pot. I you are working large flat areas its ok but on smallish complicated shapes you will regret it. Ive not had time to split it down due to work so will post the finished mould plus the infusion when time allows. I also made the V piece for my belly pan and this has to be a prime example of how good this stuff is, i wouldn't advise you do this but i made the plug in around 10 minutes and finished the job in 15. There was around 100grams of tooling gel coat left over so not wanting to waste it i cut some sign board to fit the belly pan, fillet waxed it and coated it in a couple of heavy layers of easy lease while the gel coat was cooking in the pot, as i applied it i could tell i needed to work fast banged a layer of glass putty on and a couple of layers of glass over that. I find its loads better with a layer of glass on the back, i made some frame guards for the road bike using the putty and one broke in half without the extra strength the glass gives. anyhow it turned out very well and will work a treat. Its a small part that you can hardly see so i didn't want to put a lot of time in. V piece mould. There are three small voids that are all off part, i will touch these up before lay up, i will only wet lay and low vacuum bag this part. I also made the side panel return mould. This is a tiny 1" thin edge that should be part of the side panel, when i made the three part uni system mould (still to lay up) i kept it simple by leaving this piece out, you cannot see it and the mould would have been way too complex for my limited expertise, Its a good job as its near impossible to keep the weave straight due to the size of part. Sign board edge to panel, ready to gel. Finished ready to break down. 3 layers of 200grm cf, peel ply, perforated film, cloth plus a light vac. Finished trimmed part placed in the side panel mould as would fit to panel, like i said slight weave damage but it at 1" wide its a night mare to cut and unseen. I will get the nose cone finished this week and hopefully make the finished part at the weekend, also im off work for a week on the 29th so will go for the biggie, the seat. Chris. Edited 10 Years Ago by VVS
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learn composites in three easy steps, Race GSXR 400 build (slow)

VVS - 10 Years Ago

Started on the bodywork moulds, small pieces first, hopefully learn enough before the bigger main...

VVS - 10 Years Ago

Looking good so far!! The rattle can problem is unfortunately a common one. You were lucky to get...

Warren (Staff) - 10 Years Ago

Moulds are coming along nicley, and the Bike has had a new paint job Win!, Win!! looking forward to...

davro - 10 Years Ago

Cheers davro, ive more moulds and parts done but need to find time to edit and post the pictures....

VVS - 10 Years Ago

Having had the side panel mould go belly up and repainting the other panels i broke up the laborious...

VVS - 10 Years Ago

Certainly doing a good job. One thing I would recommend which took me awhile to accept, is to make...

Hanaldo - 10 Years Ago

Wow - watching in awe - those look great. I'm glad you're not being hard on yourself regarding a few...

redeye - 10 Years Ago

Haha, those flanges are slowly getting bigger! I'm open the help, tips and criticism as learning...

VVS - 10 Years Ago

looking good, what are you using to make the flanges with? and how easy is it to bend and conform to...

scottracing - 10 Years Ago

Loving the work Chris; you've put some serious work in to get this far and it really is paying off....

Matt (Staff) - 10 Years Ago

@ Scott Hi, apart from hot glue, scissors and craft knife everything is from EC. I use filleting...

VVS - 10 Years Ago

Very clever bit of lathe work there ... excellent idea! My lathe is already running :w00t: :laugh:

Dravis - 10 Years Ago

Its really cleaned everything up and only needs a small amount of gum to seal. machined the pipe...

VVS - 10 Years Ago

Dravis, forgot to say center hole drilled at 5mm. Guessing you could play around with hole...

VVS - 10 Years Ago

Yeah, I'll experiment ... then post here ... Then EC can copy them in bulk and sell them like hot...

Dravis - 10 Years Ago

Haha, patent pending!

VVS - 10 Years Ago

THE DOUBLE INFUSION. What can I say, I will not be doing another in a hurry! The idea was simple,...

VVS - 10 Years Ago

Hi Chris, Infusion are looking nice! getting a bit keen with the double infusion ;) When I clear...

davro - 10 Years Ago

Turning the pump off wouldn't have worked either, as it isn't the pump that does the infusing, it's...

Hanaldo - 10 Years Ago

Yes having read the principle of resin being pushed in under atmospheric pressure i should know this...

VVS - 10 Years Ago

Yes you can throttle the resin feed quite easily with a line clamp. Also for cosmetic parts you can...

Warren (Staff) - 10 Years Ago

I will have a play about with a couple of small parts to get a feel so im better equipped for the...

VVS - 10 Years Ago

looking good! thanks for sharing :) keep up the good work ;)

matthieutje65 - 10 Years Ago

Had to leave the bike sad and lonely for a couple of weeks due to going to Oulton Park and Anglesey...

VVS - 10 Years Ago

For tricky little strip's of fabric like that, I suggest getting some spray adhesive from EC and...

Hanaldo - 10 Years Ago

Yes got you mate and already there. I've purchased some FusionFix™ GP and also got some pro carbon...

VVS - 10 Years Ago

Found a few hours so pulled the nose cone from the new mould....

VVS - 10 Years Ago

impressive work, I might have to buy another bike just so you can make some parts for it :)

scottracing - 10 Years Ago

Haha, still learning my trade, should have it sussed by the time I finish the bike, problem then is...

VVS - 10 Years Ago

Very nice work :) Chris Carbon fibre works LTD

carbonfibreworks - 10 Years Ago

Cheers Chris. If you remember we had a chat at EC one Saturday morning. Got to sort the lay ups...

VVS - 10 Years Ago

[quote][b]VVS (16/06/2015)[/b][hr]Cheers Chris. If you remember we had a chat at EC one Saturday...

carbonfibreworks - 10 Years Ago

Can i just say photobucket is a real pain and has a mind of its own, if the pictures are of...

VVS - 10 Years Ago

WOW!!!!!

redeye - 10 Years Ago

Great work :D I love photos during the process :cool:

Jacopo Carbonio - 10 Years Ago

Thanks guys, I'm new to this so still learning, glad you like the stuff so far. I had set up to do...

VVS - 10 Years Ago

thanks for all the great images once again! To add a little remark about the polishing of the mould,...

matthieutje65 - 10 Years Ago

That's interesting leaving the mould keyed. I think as I how some experience of working with auto...

VVS - 10 Years Ago

The result is still better than a scotch pad with 800grid moulds. So parts are coming out of the...

matthieutje65 - 10 Years Ago

Awesome job Chris, keep it up!

JRT - 10 Years Ago

99 Problems and a vac leak is one If you having vac problems I feel bad for you son I got 99...

VVS - 10 Years Ago

I feel your pain brotha lol

JRT - 10 Years Ago

Haha, I was in a dark place. If you want to make parts using composites then you will have to...

VVS - 10 Years Ago

I feel you... Strange no one has come up with some tricks to find those leaks. How about filling it...

Ronny - 10 Years Ago

Haha, they pretty much do supply that sort of service! Liquid would be a nono around your resin...

VVS - 10 Years Ago

I am yet to go down the vacuum route, but the "hearing it" comment makes me wonder if making a small...

redeye - 10 Years Ago

I have an infallible micro leak detector .. she's called Andrea and is 11 years old ... :D :w00t:...

Dravis - 10 Years Ago

Not sure about the sniffer as i believe they don't work with the very small leaks. As you can read...

VVS - 10 Years Ago

That looks fanfreeakingtastic! Wowzer man, well done, be proud. I have a tony little part I will...

redeye - 10 Years Ago

[quote] finding leaks via hearing I would have a hard time explaining myself :) [/quote] Well lol...

Ronny - 10 Years Ago

Leak detectors do work, and if you have the electrical knowledge to knock one up yourself for 30...

Hanaldo - 10 Years Ago

I think we all need an Andrea. Hoping that with a little more experience I will get less leaks.

VVS - 10 Years Ago

One problem is that not all micro-leaks make a sound ... :crying: so even an Andrea is not...

Dravis - 10 Years Ago

You know it makes sense, should definitely treat it to a carbon coat.👍

VVS - 10 Years Ago

Sorry not to have posted any of my bike build recently but i have had to leave it as ive been making...

VVS - 10 Years Ago