Hi Everyone:

I am a newbee so I suspect this will take many tries. I wish to make a kayak paddle out of carbon fiber that has a foam core - so heres my confusion

I have existing paddle and will make a split fiberglass mold.

OK so I have the mold - I can layup carbon on each side  and leave a "vent " hole at each end for the foam to come out 

NOw i pour the foam on one side close up the mold - I cant vaccum it because all the foam may go into vacuum

I could just clamp i guess but then how does each side of the carbon stick to each other and give me a finished surface

ralphey

Hi,
cure both sides separately then put the moulds together and pour in the foam, I'd recomend a foaming epoxy as it will be more durable and have better material properties than some (cheaper) 2 part foams.

Chris

When you design your pattern and mould for each side, you can design in a flange for bonding the two parts together. Recess the flange by the thickness of the carbon plus a bit for glue.  That way you have an area of overlap you can bond to secure the two halves together.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant