Help Making a Carbon Fiber "Tube"


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Raijin
Raijin
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Let me just start by saying that I'm new here and the only experience with composites I've had is some simple fiberglass lay up by hand. 

I want to make a rectangular carbon fiber tube. I've done some preliminary research here but failed to find a thread about this specific type of project. I was, however, able to determine that I probably want to use the vacuum-bagging method.

Here's a random photo I found on Google of the shape I'm going for:

http://www.rockwestcomposites.com/system/details_images/148/original/img_7547_725x191_edit.jpg?1422306359



I'm guessing the easiest way to do this would be to saw off a length of gutter (or something similar in shape) and try to vacuum bag the CF around it using an actual bag (as opposed to the usual method of taping a 'bag' sheet over the piece).

A few questions:
  • How could I get a seamless piece like in the photo above? If I use carbon fiber sheets, there's bound to be a seam line running along the piece somewhere?
  • Would you guys recommend using the carbon fiber that comes in tubular sleeves?
  • How would you pros go about making something like this?
Thanks!
Edited 9 Years Ago by Raijin
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Dravis
Dravis
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I very much doubt that the tube in the picture is "seamless" -- You can not weave "Twill" in a continous "tube" ---

If you want a cosmetic outside part like the one in the picture, AND you want 2-2 Twill, then you will have a seam ..

If you use braided tube, you will have the braided finish, that looks like plain-weave - only without 90- degree  angle to the weave .. it will usually be a steeper angle.

Also Braided hose CF is quite "open" in the weave, so the lower layers need to be a black material. (Not Glass-fibre)

I would make a split mould, and vac-bag with a pressurized rubber tube through the inside, to get a good cosmetic surface.. I.e. make a "plug", then make a mould from that.

Another option is to vac bag on a mandrel (slightly tapered) and use very carefully applied Peel-ply on the outside.. It can then be clear coated to give a good cosmetic finish.

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