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andygtt
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this is loosely how i do the return edges on my parts... if the areas are hard to get to when the mould is assembled i will often lay it into the mould section carefully and trim it right to the edge, then assemble and overlay the other side around 10mm... then if you do happen to have a void (it happens to me occasionally) then the resin still flows to the carbon edge and often fills the void and you end up with a slightly heavier part but the right shape.... much better than having a bridge that you then have to fill. great job so far, very impressive Ragged99 (15/04/2014)
Then when laying up the mould, tack the carbon down into the top moulds without the base plate in place. and trim back to edge with a couple of inches over lap, and if necessary snip the overhang edges to allow them to fold easily along the return Before fitting the baseboard , tack some carbon tape in place for the internal flange. Then fit the board and carefully lay the carbon in place from the other half in place. Then stack and envelope vac bag it in the normal way. This seems a reasonable plan, but it is a fair bit of a faffing around to get a return edge, .... am I approaching this correctly? Adrian
y) then the resin still flows to the carbon edge and often fills the void and you end up with a slightly heavier part but the right shape.... much better than having a bridge that you then have to fill. great job so far, very impressive
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Ragged99
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I should say the complete set of moulds is now complete for the bodywork created so far, including end fences and so on. So with a first pull of polyester complete we are now ready to rock for the infusion process. I'm consequently doing a test of a complex resin infusion shape, in the form of my airbox, for which I'm currently finalising the buck. Which is incidentally sitting on my G1 bodywork.  This needs to have some returns underneath the shape, and I will clearly need a two part mould for the part because of the recess. So my plan was to glue the buck on a sheet of melamine board and make a two part mould in the normal way with large flanges sticking out horizontally from the lower edge as it's shown in the photo. Then when the mould is made cut another sheet of board so that it has a hole about 1 inch smaller all around than the footprint of the buck. This should give me an "internal" return edge. Cover this second board with release tape. Then when laying up the mould, tack the carbon down into the top moulds without the base plate in place. and trim back to edge with a couple of inches over lap, and if necessary snip the overhang edges to allow them to fold easily along the return Before fitting the baseboard , tack some carbon tape in place for the internal flange. Then fit the board and carefully lay the carbon in place from the other half in place. Then stack and envelope vac bag it in the normal way. This seems a reasonable plan, but it is a fair bit of a faffing around to get a return edge, .... am I approaching this correctly? Will the epoxy infuse up and around the return edges? If I'm short of time I may go for an external return edge on the normal mould, but this will make fitting it to the parent panel a bit trickier. Cheers for the help. Adrian
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Ragged99
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Tim Has a G2 car and mine is a G1. No we're not linked to AB, except Andy Bates is a mate, and we're both long time happy customers. The car is indeed beautifully engineered and on a par with much large players in the industry, the quality puts some much better know manufacturers in the shade.
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wozza
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Teem (09/04/2014)
wozza (08/04/2014)
Nice work, is it going on a G1 or a G2 ?
WarrenBoth. (He said crossing his fingers...) T Are you connected to AB or is this totally separate? Had a chance to look over the car whilst exhibiting at Stoneleigh last year, beautifully engineered and some really nice design touches.  Warren
Carbon Copies Ltd
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Teem
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wozza (08/04/2014)
Nice work, is it going on a G1 or a G2 ?
WarrenBoth. (He said crossing his fingers...) T
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wozza
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Nice work, is it going on a G1 or a G2 ?
Warren
Carbon Copies Ltd
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wildcard
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Hanaldo
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Very nice. I think working with that much csm and polyester would give me a breakdown, hate it with a passion.
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Ragged99
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Well here's yet another update. With the moulds complete, and centre sections previously moulded with locating lugs. Tim and I set about them on Sunday afternoon with a vast quantity of polyester resin and CSM to make the first pull bodywork from the moulds. This is in hand laid up polyester (Gel plus 2 x 350GSM), mainly because Tim needs some bodywork to get out racing quickly ( he spent last weekend chewing his spanners while I went racing) and this was a quick, risk free way of doing it and seasoning the moulds, plus we're not yet ready to do a CF infusion and risk £150 quids worth of carbon+epoxy. The plan is to use these polyester sections as mould protectors once we get the CF parts made. The main question now is how much Carbon? We have a supply of 350GSM biax carbon, so one or two layers of this + Carbon Kevlar reinforcement along edges and other high load areas such as catch mount points. Plus perhaps reinforcement strips along each main "edge" in the moulding. Any suggestions on the layup or use of Soric for reinforcement and where.? Anyway what you want is pictures right? There are three flashlines on this part one up the centre and 1 about an inch in from each edge. Incidentally the "indent" areas on the centre line of both parts are to be cut out leaving a small flange to allow additional covers to be fitted.  And here's the back end .... strategic placed in Tim's hallway..
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wildcard
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Looks great! Can't wait to see the finished car!
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