Hello from Hatfield ,uk . Two weeks ago i didnt even knew anything about enfusion process and when i saw sneek prew i was impressed of quality of the finish and time that took to do it , so whatever happens i want to try an do my best to make a full fairing kit for my aprilia rsv 1000r. I know its a big job and massive chalange for my but we all where there at some point in our lives.

The nose fairing will most likely be a split mold of at least two sections, though some OE fairings seem almost designed to be taken from a single part mold!

I'm not familiar with the RSV so I couldn't comment, but it should be apparent when you look at it

Fitting lugs will have to be glued on afterwards, there's no way you can capture that detail with composites on the opposite face (well, you could use a matched tool but the lugs would be fragile)...it's an injection molding speciality. Plent of excellent products to bond to epoxy and stronger than you would think, probably best to ask in the product section.

I'd do the lower fairing panels first as they will be easiest, then when you have got to grips with the method start looking at taking a mold from the nose fairing as that will be a step up in terms of challenge.

You can make a full cf petrol tank if you are inclined, two methods....

1. you mold the top and sides in a split part mold and then mold the base seperately leaving a lip, then glue together when finished...
2. you make a plug out of foam and wet lay cloth over the top by hand, then dissolve the foam once the tank is complete.

There are details and discussions of both processes on here, it's a really big job and if you want to use the first method you will usually destroy the originla tank during the mold making process.

Good luck!

Hi, Tom. Welcome to the forum, and good luck for your project.

 



 


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Thank you very much for your reply , i did thought to start on side fairings as well ,as they are they the easyest ones from this kit , and as you say i will get more familiar with all this method ant components . I saw some of the fasteners where used on sneek prew when you guys made a carbon bonet that was awesome, i watched those vid few times and i am sure i will look at them when i will start this project. Curently organising room for this job ,shelfs ,proper heating supply to keep a decent room temperature ,ect.  I must look more into that foam molding i think you gave me a briliant idea , aprilia rsv tank unlike other bikes are made out of abs plastic.

  Thank you ones more and here are some pictures what i am about to do

and complete kit should look just like this . This bike in picture is caled aprilia rsv1000 nero , only 200 of them where made and i want to make 201

Hi , just a quick one , i've bought spare fairings for mold making (just in case i will damage them ,didnt wanted to use original ones from my bike) , so the question i wanted to ask is how many layers of carbon fibre i should use for side fairing and which thicknes ? just trying to estimate how much material i will have to order. I saw the calculation tab for the resin which is very helpful,thank you