Extended Carbon Fiber beak.....Help me design it....

Discussion in 'Parallel Universe' started by ebrabaek, Apr 15, 2011.

  1. ebrabaek

    ebrabaek Long timer

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    One layer of resin.....
    [​IMG]



    Second layer of resin..... This will ensure a smooth....auto level of the planform, taking out hrs. of sanding, thus the mold will be laid on top of this......
    [​IMG]

    Until Tomorrow.....
    #81
  2. runnin4melife

    runnin4melife Been here awhile

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    Erling,

    Just make the rally fairing please ;-)
    #82
  3. SDDinNH

    SDDinNH Ridgerunner

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    Looking good. I like this better than the extension :D
    #83
  4. ebrabaek

    ebrabaek Long timer

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    :D:D..... I will..... Just one thing at a time. My current front faring is awesome......Open visor until 70 mph, and riding season is kicking in here in the desert, so I really want to tackle this, along with the dual brake line mod.....and.....uhhmmmm.... Can you say ....The first MX Fork Sliders for the 8GS...... Goodie Goodie.:D
    #84
  5. ebrabaek

    ebrabaek Long timer

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    By far me to. I have kept the same with, (although it appears wider, it is the same with as the stock) and lines as well. I think it looks a little awkward still, but after sitting watching it for a while, it became apparent that you tend to focus on the now brighter beak. Should look good in all Carbon. It'l go on anyway, so I can ditch the low fender.
    #85
  6. runnin4melife

    runnin4melife Been here awhile

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    Going to beat me to the fork guards ehh? Haha no worries, I am going to try and merge the UFO uppers to the BMW lower bolt pattern. Will see if it works or not.
    #86
  7. ebrabaek

    ebrabaek Long timer

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    Properly not.....:D... Or at least I don't think so, as I will need to spend some time on this plug, then mould, the first cast for the bike. I still don't have brake lines, but a very capable local hydraulic hose maker, who did the front brake extensions for the Rox Risers.....are ready when I am. I am really exited to see how the CF beak tip/USD sliders will compliment each other....... He he...:freaky
    #87
  8. ebrabaek

    ebrabaek Long timer

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    Heat gun works on many plastics. As simple as the BMW guards are, you could most likely make a Aluminum jig for the lower pattern, and then just heat the UFO's with a heat gun.....:evil
    #88
  9. runnin4melife

    runnin4melife Been here awhile

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    I am not the master of plastics but wouldn't that essentially degrade the integrity? Or are you suggesting I make the pattern then use that to fab the carbon fiber ones.... Hmm :evil
    #89
  10. ebrabaek

    ebrabaek Long timer

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    Well.... you don't want to set it on fire....:D, but most plastics are of polypropylene, which you can get to about 200 deg. F., and then slowly "reform" and generally they will stay in their new form, or shape. If you bend a SS thin strip to match up the curvature, and hole pattern of each lower..... Then set the SS template in a vise, and slowly heat up the plastic, and about 180-200 try to form it over the template. It might be worth a try on a cutaway piece before you go at the main piece, but that is what I would do, with the simple mounts of the F8GS. It will not degrade the plastic. Off course I say that, but UFO make good stuff. I have done this on several plastics, although not sliders, but one Clarke fuel tank, with great success.
    #90
  11. ebrabaek

    ebrabaek Long timer

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    After two layers of resin with cure in between..... a third layer of resin was laid, and then one layer of fabric. Note how the stress was relieved in areas of high tension, by cutting of the fabric. Only one layer, as it is easier to manage one layer of 6 oz 2x2 twill, than multiple layers. You start from one side, and while massaging it into place, you sort of roll in one direction.
    [​IMG]
    #91
  12. SDDinNH

    SDDinNH Ridgerunner

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    The original has a plastic "hook" underneath it to hold it to the front of the beak. How are you going to add that, or are you just going to add a second set of bolts farther forward? :ear
    #92
  13. ebrabaek

    ebrabaek Long timer

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    I will make a CF cross brace, so that it will install in the exact same way the stock one does. It adds a little complexity to the project, but it is worth it.
    #93
  14. ebrabaek

    ebrabaek Long timer

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    As only one layer was put down first, for stress management, the subsequent layers would be laid in hard epoxy. In the past we had been told to sand first, but that is not really important, as the matrix is only a day old. What IS important is to have a smooth surface, and as fibers conform, they stretch and pull, so the real reason for my sanding is to smooth out any stickies.
    [​IMG]



    Then two more layers, and a heap full of CF scrap's were cut, and after one more full sheet, then all the scraps were laid down, followed by the final full sheet. I estimate most of the areas have 6 layers of 6 oz. 2x2 twill. Good enough to still flex a bit when separating the two pieces, and then a good foundation to strengthen the mould, as that will be explained later.
    [​IMG]
    #94
  15. ebrabaek

    ebrabaek Long timer

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    Almost time to break the mould...... Sort of like Christmas......:D
    #95
  16. SDDinNH

    SDDinNH Ridgerunner

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    :clap
    #96
  17. ebrabaek

    ebrabaek Long timer

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    Sorry fellas...... My youngest just turned 7, and part of the celebration carries through today...... M'fraid nothing until tomorrow.....:D
    #97
  18. therivermonster

    therivermonster Been here awhile

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    No worries. Party on my good man!
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  19. zgfiredude

    zgfiredude RMAR

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    Hey, the party's over, get to work!! :D
    #99
  20. ebrabaek

    ebrabaek Long timer

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    I know your in the family, with your wife now owning a sixfitty, but until you get one, you have no dispatch authority......:D:lol3.... How are you my friend..... Found what your looking for yet.....????