Carbon fiber roof - making the mold


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BlackNDecker
BlackNDecker
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Greetings all,

I bought a brand new OEM steel roof and plan to make a mold and eventually a carbon fiber roof. 

A little background...My car is a 2007 Honda Civic Si and comes with a heavy sun roof assembly (this comes standard from the factory). I contemplated simply swapping roofs for the OEM "non-sunroof" steel roof. That would save me around 20 lbs...but instead of going that direction I've decided to make a carbon fiber roof and hopefully save 30+ lbs.

Some pictures of my progress...

Made some progress on the roof project. 

Transferred it out to the garage:


The antenna hole will be covered:


And the tabs for the weather seal have to be cut off:


Luckily I have a Dremel for these types of projects:


Made some flanges:


Antenna hole covered (with a fresh coat of wax):


Flanged, waxed, and ready to go...




Unfortunately, it's going to be too humid all weekend to lay the gel coat...so I'll probably have to wait until Monday or Tuesday. fml
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Hanaldo
Hanaldo
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A lot of effort to go through for little reason. Firstly, the first layer behind the gelcoat is the critical one that you don't want voids behind. The gelcoat is what needs the support, after that first layer any voids in the mould aren't too critical. Obviously this is within reason, you don't want large areas of bridging or large/lots of voids. But regular laminating techniques, so good stippling with the brush and then going over the entire mould with a roller, will ensure that those voids don't occur. 

Secondly, you haven't got any angles there that 450g csm couldn't easily conform to. In fact, I don't see anything there that even a 850g couldn't cope with, with a bit of rolling.  Smoothing that transition out isn't worth the time and effort you out into it. Just go on with the csm.

If I might make a suggestion, that panel is quite large and flat. So I think you will find that the usual mould layup of 4-5 layers of 450g csm will still be a bit flexible. Couple options you have, one is just to live with the flex and hope it doesn't flex under vacuum and result in a distorted panel. Another option is to put  a few extra layers of 450 on. But what I would do, to save resin/expense/weight, is do 2 layers of 450g csm and then 2 layers of 850g woven rovings, followed by another layer of 450 csm. Let that cure, then if it still isn't rigid enough, laminate some stiffeners onto the back (12mm mdf is my choice, can also use cardboard tube cut in half, coremat, etc) in the direction of the flex. 

Not sure if EC have 850g woven fibreglass, they might not. In that case just go with 5-6 layers 450 and then the stiffeners on the back if they are needed. 
GO

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