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Old 01-08-2011, 08:57 AM   #1
ebrabaek OP
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Wicked Carbon/Kevlar rear luggage boxes.....It has begun....And is now finished...

I finally got it started....... After posting sort of a survey here.....
http://www.advrider.com/forums/showthread.php?t=647595

I gathered a lot of thoughts, and started. The biggest thing I would like you to take away from this.... Is how to build`em. As with my other threads here on advr......I like sharing my knowledge, realizing that not a lot of fiber heads share that thought...... I`d like to think that I do. Perhaps now would be a good time to search for my other threads...for easier start projects.....since this should not be your first go at it. You can make these composite boxes to your own liking, and specifications..... Thus bias....individual taste bears a big factor here. I don`t travel around the world.....yet... on mine, and the cases will be used for the average within 1000 miles of exploring. I have some waterproof bags I can sit on top of the rack when need be. You can off course make them as big as you want....but I want this thing to be nimble.....for single track use, and not create a barn door of resistance. So here it goes.......
There are many great epoxy`s and while most will be fine for this app....What matters are what is available to you.... But for reference and starting point.... I thought I`d mention that I get all my epoxy`s from polymerproducts. They have an ebay store where it can be had for a little less that their main site.... They are a great company....and their master alchemist`s name is Gerald..... an extremely helpful very knowledgeable guy. If you have any questions....he communicates very well.... High temp epoxy....
http://cgi.ebay.com/EPOXY-RESIN-HIGH...item483836807f

Regular epoxy.....
http://cgi.ebay.com/ws/eBayISAPI.dll...m=310150301851

Carbon Fiber source.... 5.7 oz Twill
http://uscomposites.com/shortroll.html

Kevlar....5.0 oz K49.....
http://uscomposites.com/kevlar.html

Latches.......
http://www.amazon.com/Southco-Inc-SC...6195150&sr=1-9

Extras....... Nitrile gloves....brushes....cups for mixing epoxy.....Popsicle sticks for stirring epoxy.....etc.

First you need to gather foam or other media to make a plug..... ( a mockup of the box).....which you then overlay with the composites. For you that read my Bash guard/engine skid plate..... you will recognize this same method. I got this foam from Home depot...... like a sheet of ply wood.
http://www.homedepot.com/h_d1/N-5yc1...atalogId=10053

One thing when you use polystyrene.... Make sure you get the water based contact cement..... all other contact cement will " melt the foam".

http://www.homedepot.com/h_d1/N-5yc1...atalogId=10053

Then you cut it into sections......Mine will be 14x14x8"....


Then in smaller sections........


Now I`m waiting for the temps to rise..... so I can glue them together......


Erling

ebrabaek screwed with this post 05-23-2011 at 05:07 PM Reason: finished the project.....
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Old 01-08-2011, 09:18 AM   #2
craftycoder
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You may be waiting a long time... it seems that cold is everywhere.
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Old 01-08-2011, 09:21 AM   #3
lmclamore
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You must have more time than sense Erling. Next you will be building an entire bike with this stuff!

Good luck...I am sure this will be most interesting.
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Old 01-08-2011, 09:24 AM   #4
ebrabaek OP
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Quote:
Originally Posted by craftycoder View Post
You may be waiting a long time... it seems that cold is everywhere.
He-he.... Except in the desert Southwest.....The highs should be close to 60 today.......ahhhhhhhhh.....



Erling
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Old 01-08-2011, 09:25 AM   #5
ebrabaek OP
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Originally Posted by lmclamore View Post
You must have more time than sense Erling. Next you will be building an entire bike with this stuff!

Good luck...I am sure this will be most interesting.
Perhaps your right......


Erling
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Old 01-08-2011, 10:02 AM   #6
Wolfgang55
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Do it in your house.

Hurry up we see a future here....................

Good start
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Old 01-08-2011, 04:09 PM   #7
The Griz
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I look forward to following this thread! Carbon fiber/Kevlar boxes? Hell yeah, durable as hell and light!!
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Old 01-08-2011, 04:18 PM   #8
Blagadán
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I was wondering when you'd get around to making a set of CF luggage cases....

Please..... carry on.
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Old 01-08-2011, 04:31 PM   #9
ebrabaek OP
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Quote:
Originally Posted by The Griz View Post
I look forward to following this thread! Carbon fiber/Kevlar boxes? Hell yeah, durable as hell and light!!
I had a feeling you would like this idea Griz.....



Erling
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Old 01-08-2011, 04:36 PM   #10
ebrabaek OP
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Quote:
Originally Posted by Blagadán View Post
I was wondering when you'd get around to making a set of CF luggage cases....

Please..... carry on.
I know...... It took longer than I wanted too........... But..... Here we go......


Erling
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Old 01-08-2011, 04:42 PM   #11
ebrabaek OP
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So the small 1/2 inch foam board has been cut to two blocks.......



Then back to the depot for their 2 inch board. I actually had the 1/2 inch board.....and will use it for add on`s...on the boxes....etc....


cut them a little over size...... Then glued them together...... and put it in a press.......


Then called for more HP to the press.......


Then I used the orbital sander to sand them into the rough shape.......


Then it got dark....... Tomorrow the fun begins....... and the shaping is up. I must admit.... That is my favorite part........ Gotta re weld the SS. rack a little...so tomorrow will be fun....... Until then.......


Erling
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Old 01-08-2011, 05:48 PM   #12
EnderTheX
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Cool stuff! Do you prefer sanding? I know this is easy and allows you to control the shape well but it isn't too fast.

I've always been fascinated by hot-wires and how they cut foam, is it possible for that type of foam?
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Old 01-08-2011, 05:49 PM   #13
ebrabaek OP
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Just ordered one 1 gal rotopax fuel, and one 1 gal rotopax water can....they will mount one behind each case.........



Erling
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Old 01-08-2011, 05:52 PM   #14
ebrabaek OP
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Originally Posted by EnderTheX View Post
Cool stuff! Do you prefer sanding? I know this is easy and allows you to control the shape well but it isn't too fast.

I've always been fascinated by hot-wires and how they cut foam, is it possible for that type of foam?
Actually..... With 60 grit....It rip`s......and you have to be careful.....It`l eat the foam fast..... Hot wire is good.... If you have the setup..... The main boxes was too big to fit in the band saw......... It only took me 10 minutes to sand them both. When I begin the shaping tomorrow.... I`l rough cut the angels with a wood saw....then sand.... Yepeeeeee....

Erling
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Old 01-08-2011, 07:55 PM   #15
MTrider16
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Can't wait to see the results. Perhaps I'll need to replace my Vario's.

David
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