Fun With Carbon Fiber - Page 8

therivermonster · 10-07-2012, 09:30 AM

Quote:

Originally Posted by ebrabaek

Home Depot..... Spray bottle...... Fill with acetone..... A few squishes..... Just like if you are misting flowers..... Done.

Thanks, Earling! I'm all set with the acetone sprayer for the exhaust mold and layup. I'll report back on how it works.

Quote:

Originally Posted by 100mpg

the clear CF.

Any paint design over the CF doesn't look right to me.
400 is a good start. When I painted my little trailer I went up to 2000 (wet, with a touch of soap in it) after every coat of paint and clear. The result with a super smooth finish and that is what you need to make a good plug and mold. Let me brag...I mean show you what I mean.

From this

To this. With spray cans.

I have thought about using this trailer to make a form to create a longer version of this to tow behind my pickup when going camping. I like the wheels tucks under the body.

That little trailer is awesome, 100! Very nice job! It's kind of amazing what quality you can get with rattle can paint.

I hear ya about getting an A1 finish for a plug which brings us to my next post. Read below.

Twin-Shocker, are you with me??

therivermonster · 10-07-2012, 09:40 AM

I took some time this morning to finish the exhaust shroud plug. I wanted an A1 finish as it's called.

This is a sample of the finish before I started sanding and polishing. Notice the nice orange peel finish.

Next I sanded with 800, 1500, 2000, then buffed with buffing compound, then polish. The results are fantastic.

The overhead lights reflect almost like a mirror.

So we went from a semi rough (nicked, scratched) shroud, to a smoothed, and polished plug.

The idea is that when I paint on the coat of epoxy onto the plug when I begin to make the mold, the very smooth shiney surface of the plug will be transfered to the epoxy surface. That smooth, shiney mold surface will then in turn allow me to creat a CF part that also has a very smooth and shiney surface. The finish work shows through to all parts. We'll see how it goes...

Comming soon... Making the mold from the polished shroud plug. Good times!!!

kirkster70 · 10-07-2012, 09:53 AM

Very nice work! I am really enjoying your thread!

I find it simply amazing what I can learn by reading the threads in this forum. Thanks for taking the time to post up as you go.

Keep up the good work!

therivermonster · 10-07-2012, 10:00 AM

Quote:

Originally Posted by kirkster70

Very nice work! I am really enjoying your thread!

I find it simply amazing what I can learn by reading the threads in this forum. Thanks for taking the time to post up as you go.

Keep up the good work!

Thanks, Kirkster! I am really enjoying doing this stuff and sharing it with you all. Don't forget to check out all the resources on the first page for WAY mor learning. Ebrabaek's posts are my primary motivation. He has done a lot for the DIY composites scene here on ADV and TT.

If you are thinking about giving this a shot, do it! Don't wait any longer. If it looks hard to you, it's not. I'm serious about this. Like Nike says, Just Do It!

If you have any questions about how to get started, just post them up here on the thread.

100mpg · 10-07-2012, 11:22 AM

Quote:

Originally Posted by therivermonster

That little trailer is awesome, 100! Very nice job! It's kind of amazing what quality you can get with rattle can paint.

I hear ya about getting an A1 finish for a plug which brings us to my next post. Read below.

Twin-Shocker, are you with me??

thanks!
and POW! You hit a home run. That looks fantastic and will make a great mold. Did you notice how the 2000g paper was smooth then suddenly started to "stick" to the surface? I am only guessing but it seems that the last of the orange peel creates a suction to the sandpaper and it suddenly disappears and become like glass. I knew I was almost done sanding when that happened!
I am looking forward to seeing the finished part.

Quote:

Originally Posted by therivermonster

I
Next I sanded with 800, 1500, 2000, then buffed with buffing compound, then polish. The results are fantastic. The overhead lights reflect almost like a mirror.

Comming soon... Making the mold from the polished shroud plug. Good times!!!

ebrabaek · 10-07-2012, 11:39 AM

Regarding the acetone spray.... Have a look here.... It about cover many items, as it takes you through a complete cycle....

">

therivermonster · 10-07-2012, 06:23 PM

Quote:

Originally Posted by 100mpg

thanks!
and POW! You hit a home run. That looks fantastic and will make a great mold. Did you notice how the 2000g paper was smooth then suddenly started to "stick" to the surface? I am only guessing but it seems that the last of the orange peel creates a suction to the sandpaper and it suddenly disappears and become like glass. I knew I was almost done sanding when that happened!
I am looking forward to seeing the finished part.

Thanks 100. I want to do a good job on this part. There's a lot left to do, so we'll see how it goes.

I did notice the suction effect with the 2000 grit. It's kind of a funny thing.

Quote:

Originally Posted by ebrabaek

Regarding the acetone spray.... Have a look here.... It about cover many items, as it takes you through a complete cycle....

">

Thanks again, earling!

therivermonster · 10-07-2012, 06:45 PM

I decided to lay up the mold for the exhaust shroud today, but I had a big issue to deal with that I didn't think about before. Holes...

These holes.

So I decided that I would stuff the cavity below the shroud with grocery bags...

And use non drying clay to fill the holes.

Then I waxed the plug with Partall paste wax...

...followed by a couple coats of PVA.

With my workstation all set I got started. I applied the first coat of epoxy...

...and used some of the yarn from the fiberglass cloth to fill the corner between the plywood and the part.

Next I layed up 5 layers of 8.5 OZ 2x2 twill fiberglass fabric over the plug. This is the finished result.

I am really concerned about bubbles. Look at this picture; there's lots of those little guys in there.

Now that I am gaining some experience, I made sure to have an ample supply of Coors Banquet beer with me.

Now we'll let the layup sit for a day or so, then pop it off, trim it up, clean it up, and hopefully lay up a cf part soon.

Thoughts:

Making a quality plug has been a great experience and great practice. I think that the mold will turn out OK, but not great because of bubbles.

I had thought that I would just make molds from epoxy, but the more experience that I get, the more gell coat and chopped strand mat makes sense to me as mold making components.

I think that I'll order up some poly tooling gell coat and some mat for the next mold project.

Anyhow, more to come soon!!

ebrabaek · 10-07-2012, 08:30 PM

Thought I'd share this picture. Just today started a new project.....and only used water, and soap to clean the part ( plastic Beak from a F800GS) and then release agent (two layers) then two layers of Max Clr-Hp.... No orange peel, after the two layers of clear coat....... that,s after the beak has seen over 3 years on the road......

Until then....

therivermonster · 10-07-2012, 09:11 PM

Quote:

Originally Posted by ebrabaek

Thought I'd share this picture. Just today started a new project.....and only used water, and soap to clean the part ( plastic Beak from a F800GS) and then release agent (two layers) then two layers of Max Clr-Hp.... No orange peel, after the two layers of clear coat....... that,s after the beak has seen over 3 years on the road......

Until then....

Nice!

What kindo of soap did you use?
Two coats of PVA, right?
How long after application of the resin to the part did you snap this pic?
Did you follow up the resin with glass or carbon?
Is this the 800 beak extension that I have read about? If yes, are you posting a thread?
Also, that resin looks pretty bubble free. How'd you manage that?

Rock on, man!

ebrabaek · 10-08-2012, 05:35 AM

Quote:

Originally Posted by therivermonster

Nice!

What kindo of soap did you use?
Any household dish washing detergent will do fine.

Two coats of PVA, right?
Right...Two coats.

How long after application of the resin to the part did you snap this pic?
Couple of hrs.... Did not change from the brush up, and should not.

Did you follow up the resin with glass or carbon?
Nothing yet, as you do not want to disturb The Clear coat.

Is this the 800 beak extension that I have read about? If yes, are you posting a thread?
Yes.
Also, that resin looks pretty bubble free. How'd you manage that?
First batch was degassed with the vacuum chamber.... Second layer was set under a heat lamp for 5 minutes with a start temp of 85 deg. F. No degas.... Stubborn bubbles was removed with a spray or two of acetone.

Rock on, man!

Ironically, the first few seconds after acetone spray, it will orange peel, but it auto levels after 30-60 seconds.

Yes... new thread...

http://www.advrider.com/forums/showthread.php?t=678072

therivermonster · 10-08-2012, 06:42 AM

Quote:

Originally Posted by ebrabaek

Ironically, the first few seconds after acetone spray, it will orange peel, but it auto levels after 30-60 seconds.

Yes... new thread...

http://www.advrider.com/forums/showthread.php?t=678072

Earling, when you degas the resin with vacuum, does it help keep the bubbles out a lot, or are a lot more introduced when you brush the resin on?

Were you in the process of making a mold in the pic you posted?

ebrabaek · 10-08-2012, 07:15 AM

Quote:

Originally Posted by therivermonster

Earling, when you degas the resin with vacuum, does it help keep the bubbles out a lot,
Yes.......

or are a lot more introduced when you brush the resin on?
Just a little, but with care they can be minimized,and acetoned out.

Were you in the process of making a mold in the pic you posted?

Yes.....

therivermonster · 10-08-2012, 07:25 AM

Quote:

Originally Posted by ebrabaek

Yes.....

Sweet!!! I can't wait to see more of your process.

I popped the mold this morning and it looks pretty good besides a number of bubbles (now holes) in the surface of the mold. I have some Cabosil on the way, but I may just mix some talc with epoxy to fill the holes, sand, spray with clear coat, sand, polish and then lay up the carbon. Of course I'll post pics of the popped mold and the finishing process...

I need a vacuum pump now...

ebrabaek · 10-08-2012, 08:26 AM

Quote:

Originally Posted by therivermonster

Sweet!!! I can't wait to see more of your process.

I popped the mold this morning and it looks pretty good besides a number of bubbles (now holes) in the surface of the mold. I have some Cabosil on the way, but I may just mix some talc with epoxy to fill the holes, sand, spray with clear coat, sand, polish and then lay up the carbon. Of course I'll post pics of the popped mold and the finishing process...

I need a vacuum pump now...

http://www.ebay.com/itm/Vacuum-Chamb...item20cc241934

10-07-2012, 09:40 AM	#107
therivermonster ^OP Gnarly Adventurer Joined: Sep 2010 Location: Federal Way WA, South Puget Sound Area Oddometer: 290	Exhaust Shroud Plug Finishing... I took some time this morning to finish the exhaust shroud plug. I wanted an A1 finish as it's called. This is a sample of the finish before I started sanding and polishing. Notice the nice orange peel finish. Next I sanded with 800, 1500, 2000, then buffed with buffing compound, then polish. The results are fantastic. The overhead lights reflect almost like a mirror. So we went from a semi rough (nicked, scratched) shroud, to a smoothed, and polished plug. The idea is that when I paint on the coat of epoxy onto the plug when I begin to make the mold, the very smooth shiney surface of the plug will be transfered to the epoxy surface. That smooth, shiney mold surface will then in turn allow me to creat a CF part that also has a very smooth and shiney surface. The finish work shows through to all parts. We'll see how it goes... Comming soon... Making the mold from the polished shroud plug. Good times!!! __________________ My Virgin ADV Trip Rocks Flyin', Me Cryin', and God Looking On - A WABDR Adventure Fun With Carbon Fiber

10-07-2012, 11:39 AM	#111
ebrabaek Beastly Adventurer Joined: Jan 2010 Location: El Paso,NM Oddometer: 2,786	Regarding the acetone spray.... Have a look here.... It about cover many items, as it takes you through a complete cycle.... "> __________________ Erling

10-07-2012, 06:45 PM	#113
therivermonster ^OP Gnarly Adventurer Joined: Sep 2010 Location: Federal Way WA, South Puget Sound Area Oddometer: 290	Makin' a mold... I decided to lay up the mold for the exhaust shroud today, but I had a big issue to deal with that I didn't think about before. Holes... These holes. So I decided that I would stuff the cavity below the shroud with grocery bags... And use non drying clay to fill the holes. Then I waxed the plug with Partall paste wax... ...followed by a couple coats of PVA. With my workstation all set I got started. I applied the first coat of epoxy... ...and used some of the yarn from the fiberglass cloth to fill the corner between the plywood and the part. Next I layed up 5 layers of 8.5 OZ 2x2 twill fiberglass fabric over the plug. This is the finished result. I am really concerned about bubbles. Look at this picture; there's lots of those little guys in there. Now that I am gaining some experience, I made sure to have an ample supply of Coors Banquet beer with me. Now we'll let the layup sit for a day or so, then pop it off, trim it up, clean it up, and hopefully lay up a cf part soon. Thoughts: Making a quality plug has been a great experience and great practice. I think that the mold will turn out OK, but not great because of bubbles. I had thought that I would just make molds from epoxy, but the more experience that I get, the more gell coat and chopped strand mat makes sense to me as mold making components. I think that I'll order up some poly tooling gell coat and some mat for the next mold project. Anyhow, more to come soon!! __________________ My Virgin ADV Trip Rocks Flyin', Me Cryin', and God Looking On - A WABDR Adventure Fun With Carbon Fiber therivermonster screwed with this post 10-07-2012 at 07:00 PM

10-07-2012, 08:30 PM	#114
ebrabaek Beastly Adventurer Joined: Jan 2010 Location: El Paso,NM Oddometer: 2,786	Thought I'd share this picture. Just today started a new project.....and only used water, and soap to clean the part ( plastic Beak from a F800GS) and then release agent (two layers) then two layers of Max Clr-Hp.... No orange peel, after the two layers of clear coat....... that,s after the beak has seen over 3 years on the road...... Until then.... __________________ Erling

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10-07-2012, 09:53 AM	#108
kirkster70 moto junkie Joined: Aug 2008 Location: Virginia Oddometer: 1,637	Very nice work! I am really enjoying your thread! I find it simply amazing what I can learn by reading the threads in this forum. Thanks for taking the time to post up as you go. Keep up the good work!