Westfield parts from a newbie


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wozza
wozza
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Brian2fast (18/02/2014)
Cheers Wildcard!



I'v been thinking about whats caused those bubbles. Would it be the first signs of bridging? I was quite sure when laying up the fabric and peel ply that everything was neat and pushed into corners but when it comes to the mesh I'm paranoid about missing areas and ending up with dry spots so I probably go overboard with the mesh. ending up with lots mesh overlaps and of cuts. I'm wondering if this could cause the mesh to lock together and cause bridging?
My question is, does every single area require to be covered with mesh? Or is there something else other than mesh that can be used, something that conforms to tight corners and compound curves better? Can Soric be used as a flow media (above the peel ply)?

How many people use MTI hose and is it worth using? I'm guessing MTI hose wouldn't have helped with these bubbles??



Thanks 
Craig


Looking at the thickness of the resin it certainly looks like bridging to me. The resin has tried to fill the void between the cloth and the mould surface. On shapes like that I would probably do the recessed section as a separate piece of cloth (circle) to reduce the chance of bridging. I would also do the same with the flow mesh. Soric acts well as a flow medium so you don't need the flow mesh. Just remember that infusion using Soric will take longer than when using flow mesh so you may need to use slow hardener.
Hope that helps.

Warren

Carbon Copies Ltd
Brian2fast
Brian2fast
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Thanks Warren

Just to clarify. When I was talking about Soric as a flow media I was meaning can it be used instead of mesh, on top of the peel ply and not between layers of carbon? I'v never used Soric but I imagine it can be pushed around compound curves much better than the mesh?

Craig
wozza
wozza
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Brian2fast (18/02/2014)
Thanks Warren

Just to clarify. When I was talking about Soric as a flow media I was meaning can it be used instead of mesh, on top of the peel ply and not between layers of carbon? I'v never used Soric but I imagine it can be pushed around compound curves much better than the mesh?

Craig


Hi Craig, never tried that. The problem I see with putting the Soric on top of the peel ply and not in the stack is that once cured the Soric will be rigid with resin making removal from the part extremely difficult if not impossible. Any reason you don't want Soric in the stack?
I use Soric in many of my parts, one to add strength/stiffness and two to remove the need for flow mesh making the lay-up easier especially on complex shapes. For something like a tranny tunnel I would certainly want a core of some kind in there especially with a prop spinning an inch or so from my leg.
I have done a couple of tunnels for "7" type cars, with a bit of thought and the right lay-up you can actually make it part of the space frame and remove quite a few of the chassis tubes in the quest for weight savingSmile

Warren

Carbon Copies Ltd
wildcard
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Did you adhere the flow mesh with spray tac? I ask because spray tacking the mesh, along with the carbon in those tight areas may reduce or eliminate the problem. 
combustioncraig
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I am really impressed with your pedals that was really cool set up and use of a compression mold.  
Brian2fast
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Hi All

Just finished the gear stick tonight. Old steel shaft and Momo carbon gearknob (expensive gearknob!) was 470g, new carbon stick saves 300g.

http://www.talkcomposites.com/Uploads/Images/815021c1-0126-49a6-abc9-f770.JPG


The main flat lever section is hollow, made by glueing 2 flat plates with spacer plates inbetween.

http://www.talkcomposites.com/Uploads/Images/daa58854-18c7-4660-a18f-226e.JPG


Little M3 st/st black countersunk bolts attaching the tube handle. Used a Permagrit countersinking tool, worked great.

Craig
Matthieu Libeert
Matthieu Libeert
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Do you have some more details about how you've made the gear stick? Smile great work btw!

Matthieu Libeert
Founder MAT2 Composites X Sports
website:
www.mat2composites.com




Brian2fast
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Hi Matthieu

Yes my description was a bit vague! Haha
Unfortunately I didn't take a photograph while I was bonding it together.

http://www.talkcomposites.com/Uploads/Images/dfd78f84-6f33-49d0-a3a4-600f.JPG


I used this steel mould with polished alu surfaces to make a flat plate of carbon about 3mm thick. Then I cut out two rectangles the size of the finished lever. Then cut strips of carbon (from the same flat plate) about 5mm wide and used these to make a picture frame arrangement around the outside of one of the rectangles and glued the other rectangle on top as a sandwich. Left it in a vice for a day. The glue squeezes out the side but as long as there are no voids in the glue or spacers when it is sanded into shape with a Permagrit block then polished up you can't see any joins. It looks like a solid part.



http://www.talkcomposites.com/Uploads/Images/8030dea2-8f14-4d43-8db5-c107.JPG








http://www.talkcomposites.com/Uploads/Images/163b35b2-2133-4b6b-89d1-9e48.JPG


I found an old three part mould I used last year in a similar way to make a bracket. 3mm steel plate welded into shape and 1.6mm aluminium plate polished and glued onto the steel. Squashed together in a vice and with G-clamps.

http://www.talkcomposites.com/Uploads/Images/3fcc4e30-6841-4e46-b397-68c2.JPG


Bracket shown top right. I glued two triangle webs to help support the horizontal and it was really strong. Four layers of 450gpm I think it was.



Craig
wildcard
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looks gorgeous!
Brian2fast
Brian2fast
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Hi All

This will probably be my last update with new parts this year, hopefully i'll be bolting the car back together again.

http://www.talkcomposites.com/Uploads/Images/740f9231-973f-48db-aa72-fd21.JPG


These are the old steel parts. Gear linkage on the left and one headlight bracket on the right.

http://www.talkcomposites.com/Uploads/Images/ee256297-a89d-46cf-b54c-271f.JPG


Carbon versions saved 400 grams. Headlight brackets are roll wrapped carbon tube and a bit of angle I moulded and bonded together.

http://www.talkcomposites.com/Uploads/Images/4009a0cb-311e-4e58-906e-a42b.JPG


One bracket with a headlight bolted in position.

http://www.talkcomposites.com/Uploads/Images/4bc28cc7-1591-4745-bb9f-1ff1.JPG


The final collection of parts made this winter. Still need to cut slots in the transmission tunnel for the handbrake and gearstick and then clear coat it.



Craig
GO

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