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-   -   Fixing My KLR650 Shrouds (http://www.advrider.com/forums/showthread.php?t=852898)

zoomzu 01-03-2013 08:46 AM

Overlaying carbon/Kevlar cloth on KLR650 shrouds
 
So my friend starts talking about composites/carbon fiber stuff. So I get on-line and start looking at materials. I come across this blue hybrid carbon/kevlar cloth.:deal

http://i688.photobucket.com/albums/v...ps0f320f16.jpg

My shrouds need fixing/replacing. At almost $200 a side.....fix them it is. Now that the overnight temp is in the 20's, good time to work on them.

http://i688.photobucket.com/albums/v...ps8ae96e28.jpg
http://i688.photobucket.com/albums/v...psc0085018.jpg
I tape up the out side.
http://i688.photobucket.com/albums/v...ps2d9bfaf2.jpg
And fiberglass the inside.
http://i688.photobucket.com/albums/v...ps42894579.jpg
On the other side I used a small piece of kevlar my friend gave me. That's the yellow stuff.
http://i688.photobucket.com/albums/v...ps76a6ae05.jpg
http://i688.photobucket.com/albums/v...ps6af8cfc9.jpg
Since I'm not worried about weight or how it looks on the inside, I just slap it on. Just want to get structure back.
http://i688.photobucket.com/albums/v...ps30eb85dd.jpg
After some filling and sanding on the outside looks like I'm ready for the overlay.:clap
http://i688.photobucket.com/albums/v...ps6fef652a.jpg
I do like the flat look though.
http://i688.photobucket.com/albums/v...ps16598773.jpg
That's not going to happen. They are getting some cloth.
So my buddy is going to help with the overlay, since he has been self teaching do's and do nots, and with alot of help from you fine inmates here. This is his road to learning/experimenting. Just a little light reading.:norton
http://www.advrider.com/forums/showthread.php?t=828372
This weekend should be the moment of overlay.

therivermonster 01-03-2013 10:26 AM

Sweet!! We'll be slangin' resin in no time. :D

Edit: I actually just saw the pictures, Mike (no pics show up at work) and they look great! The FG and Kevlar seem to be holding those cracks together quite well. Once you filled the cracks from the outside, those babies look ready for some overlay.

One thing that you could do before you start cutting into that beautiful fabric is to make a pattern out of an old bed sheet or similar large piece of drapable fabric. You'll want to take into account the wrap around the sides, and the hole in the middle. You'll probably want to wrap around all the edges about two inches in order to ensure that the fabric that is showing has good weave and no loose strands. We may also have to make reliefe cuts in the middle hole to get the fabric to lay nicely, but we can wait and see how well it wants to conform to the shape of the fairing.

Nice pics btw. Keep em comming.

I'm off to sewing class now... *THATS RIGHT! I SAID SEWING CLASS!!* :eek1

zoomzu 01-05-2013 10:31 PM

Overlaying kevlar/carbon cloth on KLR650 Shrouds
 
Getting ready to put some cloth on.
http://i688.photobucket.com/albums/v...ps27eb6d4e.jpg
Slathered up the shroud with some epoxy to stick the cloth to.
http://i688.photobucket.com/albums/v...ps372d2f96.jpg
Overlayed the cloth on had some problems getting the cloth to stick to the backside. Wanted to wrap over the edges. The cloth wouldn't stick with epoxy so we cut the cloth. I'm hoping to still get a smooth edge after all the epoxy sanding and clear coating. So far it's not too bad. In hind site I would've taped the cloth to the back, and after the first coat cured. I would have epxoied the back side.:doh
http://i688.photobucket.com/albums/v...ps7bff35c8.jpg
Here's after I trimmed them up after the first coat cure.
http://i688.photobucket.com/albums/v...pse6e300cc.jpg
http://i688.photobucket.com/albums/v...ps8d5d8952.jpg
Here's a close up with a wet third coat. I still have a bunch of sanding to do to get them smooth. But they are starting to look pretty good.:thumb
http://i688.photobucket.com/albums/v...ps404b6e6f.jpg

zoomzu 01-06-2013 07:33 AM

After the 3rd coat cured I did a little light sanding, to knock down some high points. immediately after I start sanding, I see blue. I'm sanding the Kevlar. I don't want to sand through the fabric so I keep it light.
http://i688.photobucket.com/albums/v...psfe09b760.jpg
I guess more coats to get some build up.:huh

When I trimmed the ends I used a Air dia. grinder with a carbon cut off wheel. and a respirator.

therivermonster 01-06-2013 12:24 PM

Those are looking good, Mike. That Kevlar seems to be a bit of a trouble maker when it comes to cutting. To be honest, I'm not looking forward to cutting it myself.

Keep the pics comming.

bwalsh 01-06-2013 09:35 PM

Quote:

Originally Posted by zoomzu (Post 20409403)
After the 3rd coat cured I did a little light sanding, to knock down some high points. immediately after I start sanding, I see blue. I'm sanding the Kevlar. I don't want to sand through the fabric so I keep it light.

First, They turned out real nice!


Second, It's a little late now but...

The thing to do when using Kevlar is add one(or more) 6oz layer of FG cloth on top of the Kevlar for a final layer. Lay both(or however many you are using) pieces at the same time. When it dries you will never see the FG, just the Kevlar. Then you have some leeway for sanding/smoothing/polishing, etc.
To do it now, you would have to sand the Kevlar for the new epoxy/FG to adhere. The problem with that, as you probably have already seen is, the Kevlar will start to fray.

You may get by with ever so lightly hand sanding and applying a top layer of FG, if you choose to do so. It may also be very time consuming.

Good luck! :freaky

bwalsh 01-06-2013 09:40 PM

Quote:

Originally Posted by therivermonster (Post 20411806)
Those are looking good, Mike. That Kevlar seems to be a bit of a trouble maker when it comes to cutting. To be honest, I'm not looking forward to cutting it myself.

Keep the pics comming.

Good scissors are the key! I have a pair of dressmakers scissors for cutting Kevlar. Similar to these...
http://www.garrettwade.com/images/500/02G0401.jpg

They work but there are scissors specifically made for cutting Kevlar...
http://64.90.29.61/usrimage/kevlar_woven_500.png

As always, never use them for cutting ANYTHING else.

kubiak 01-07-2013 08:54 AM

nice job on the shrouds!

zoomzu 01-07-2013 03:21 PM

Quote:

Originally Posted by bwalsh (Post 20415655)
First, They turned out real nice!


Second, It's a little late now but...

The thing to do when using Kevlar is add one(or more) 6oz layer of FG cloth on top of the Kevlar for a final layer. Lay both(or however many you are using) pieces at the same time. When it dries you will never see the FG, just the Kevlar. Then you have some leeway for sanding/smoothing/polishing, etc.
To do it now, you would have to sand the Kevlar for the new epoxy/FG to adhere. The problem with that, as you probably have already seen is, the Kevlar will start to fray.

You may get by with ever so lightly hand sanding and applying a top layer of FG, if you choose to do so. It may also be very time consuming.

Good luck! :freaky

Thanks for the info, if there is a next time I'll try that. I don't think I will this time around.

zoomzu 01-07-2013 03:26 PM

Quote:

Originally Posted by bwalsh (Post 20415685)
Good scissors are the key! I have a pair of dressmakers scissors for cutting Kevlar. Similar to these...
http://www.garrettwade.com/images/500/02G0401.jpg

They work but there are scissors specifically made for cutting Kevlar...
http://64.90.29.61/usrimage/kevlar_woven_500.png

As always, never use them for cutting ANYTHING else.

I have some Clauss kevlar scissors. They work great.

Quote:

Originally Posted by kubiak (Post 20418367)
nice job on the shrouds!


thanks, I have a bit more that I want to do. Make them all shiny.:D

bwalsh 01-07-2013 05:43 PM

Quote:

Originally Posted by zoomzu (Post 20421522)
Thanks for the info, if there is a next time I'll try that. I don't think I will this time around.

I don't blame you. I wouldn't either. What you have will last a long time.


Quote:

Originally Posted by zoomzu (Post 20421550)
I have some Clauss kevlar scissors. They work great.

The second pic was one I grabbed on line and were NOT Kevlar scissors. :baldy
The Clauss scissors look like the hot ticket!

zoomzu 01-09-2013 03:38 PM

Ok, just about layered up, and I'll start sanding to get it smooth.
http://i688.photobucket.com/albums/v...psa2e42642.jpg

the thing I like about this cloth is one direction it reflects blue. In the other the carbon.
http://i688.photobucket.com/albums/v...ps7cf92cce.jpg

This is my trouble area. I may just leave this semi bumpy.
http://i688.photobucket.com/albums/v...ps01b38570.jpg

I think it will still look ok. Besides from 10' nobody will know anyway. It is a KLR, not one of those over priced bikes you're scared to get dirty.:wink:

bwalsh 01-10-2013 08:14 AM

Quote:

Originally Posted by zoomzu (Post 20439853)
I think it will still look ok. Besides from 10' nobody will know anyway. It is a KLR, not one of those over priced bikes you're scared to get dirty.:wink:

They look great! Do you have a link for where you bought the material?

zoomzu 01-10-2013 08:43 AM

Quote:

Originally Posted by bwalsh (Post 20445402)
They look great! Do you have a link for where you bought the material?

I bought the cloth on ebay, but you can also get it here.

http://www.uscomposites.com/

zoomzu 01-10-2013 08:46 AM

I'm about 90% done sanding on one side.:clap

http://i688.photobucket.com/albums/v...ps13b3e40c.jpg


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