Carbon wet vacuum layup on wood


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Dentex
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Hy guys. 
I work on a project that requires wraping wooden tapered ellipsoid object in 2 layers of carbon fiber. Carbon is added for stiffness and visual appearence so nice layup is must.

Carbon goes from bottom of part and goes on sides, it doesnt go all the way around.

I have to use wet layup method combined with vacuum so my plan is to:
1. Cover wood with black tinted epoxy
2. Wait for tacky stage and add first layer
3. Add resin to saturate fabric
4. Wait for tacky stage to add other layer
5. Add resin to saturate fabric
6. Place peel ply and breather and use around 20% vacuum to remove excess resin

My questions are:
1. Will 20% vacuum remove excess resin since most of resin reached tacky or beyond tacky stage?
2. Is there anything to change in the process to ensure good bond and appearance?
3. Process is like skinning with carbon only using 2 layers instead of one and using vacuum to remove excess resin. Should I do like plan above or should I do 1 layer, wait it to cure, key whole surface and repeat process for 2nd layer?

Thanks Smile
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Chris Rogers
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I agree with Fasta on the doing both in one shot and not letting it gel between plies.  You should be able to get a tight-enough part with less than full vacuum - but it would be easier to use perforated film and a bit more vacuum especially if you have groove features that might need more pressing.  

If you need to vacuum (it will be more compact and will reduce the likelihood of bubbles which will make your finishing hard - especially with grooves) it is good to make sure that all the wrinkles or pleats of the bag are in the off-the carbon bottom or back part.  You want to be able to pull the bag tight so wrinkles in the bag don't print into the part - but not so tight that it bridges the grooves.  Peel ply cut on the bias can help avoid wrinkles too - as will a thinner breather/bleeder like bias-cut light fiberglass cloth.  Going over the bag after its pulled down and pressing the bag into the grooves very evenly will help.  Without a picture or sketch it's hard to know precisely what the shape it - so this is guessing.

It's probably going to be necessary to use some clear primer or high build coat of epoxy to finish before you apply a final coat of UV blocking topcoat. 

The downside of using thin peel ply and wrapping it is that unless you have nicely sliced peel ply it will leave a mess on the edges that will make finishing harder.  Also - the grooves will bridge.  A long drape of bias-cut nylon peel ply over the leading edge and carefully pressed into the laminate - a dry chip brush is great for this - just start at the "nose" and work down.  You didn't mention the orientation of the carbon +/-45 to the tube will conform most easily but 0/90 will look way better if it's twill.

Good luck - and please follow up with pictures if you can!




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