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

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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	Can i just say photobucket is a real pain and has a mind of its own, if the pictures are of different sizes and orientation then please forgive me, I've spent hours trying to upload and edit only to find it saves what ever it chooses. Still not made the time to make the the seat mould but I've polished the seat and started to cut some of the flanges, In the mean time I set up to make the rear hugger and front mudguard. Rear Hugger. Bagged the hugger having laid the mould with one 200grm pro carbon, two layers 200grm twill, peel ply and mesh. Through connectors are doing the business and stopping the micro leaks. Resin infusing and looking good. Infusion finished, everything went as planed and i was looking forward to breaking the part out. RIGHT, again three slight pulls in the part. Paul at EC kindly de moulded the part and I was a little miffed at the marks as I'd been super careful when I laid everything up. As soon as I went through the process with Paul and told him I'd used the pro carbon he stopped me and explained that this was the probable cause of weave pulls. TRICKS OF THE TRADE. You learn every time you touch this stuff. Paul showed me a little trick with the pro carbon. It doesn't like compound curves and so a little heat applied using a hot air gun is needed. Lay the CF and then gently warm it with the heat gun, this softens it enough to get a nice drape with no pulls. Will it work!!!! Front Mudguard. With my new found skills I got stuck in. I have used the two different types of mesh, the soft is VERY difficult to remove so i only used it in the square centre of the mudguard. All bagged up ready for resin. Resin infusing. You can see the different flow rate of the different mash types, soft mesh is in the middle. Another picture later on during the infusion, you can see that the soft mesh wets out slower than the normal mesh by the white spot in the middle. Finally a part that im 100% happy with! Mudguard looks great. Again I'm learning and moving in the right direction. Paul has kindly offered to do another hugger with me to see if he can iron out a few of my bad habits, Where else would you get that sort of service. Nose cone mould is polished so I will be making the finished part in the next week or so. Chris.
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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

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