How to make your own Carbon Fiber fairing....

Discussion in 'Parallel Universe' started by ebrabaek, Aug 29, 2010.

  1. MSH

    MSH The Salt

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    Just start making two of everything. You can give me the "less nice" of the two and I will pay for supplies. :super
    #21
  2. ebrabaek

    ebrabaek Long timer

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    :D:D.....
    :thumb:thumb

    Erling
    #22
  3. GSranger

    GSranger blacksheep

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    E... I'm surprised you didn't make your GPS mount detachable in case you ever upgrade to a newer/different model :huh

    I'm not doubting you already thought of this. You are definately the man with a plan :bow
    #23
  4. ebrabaek

    ebrabaek Long timer

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    Funny you should mention this.... I actually did think of it.... But the mount took me 30 minutes to make......And my thought was..... Most of the garmins have the same mount.....like I can fit my wife`s 260w in that same mount....But to engineer a little bar the mount need to sit on......to be able to countersink the mounting screws.....Etc.... It would by far be easy to make another mount ...which I would need to in case of a different brand gps install.....Just grind down the exsisting mount.....install the new one. Just another benefit of this stuff........ Something goes wrong.....pit it at the grinder........he-he......Don`t ask me how I know this.....:rofl:rofl
    :thumb:thumb

    Erling
    #24
  5. GSranger

    GSranger blacksheep

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    ME YOU
    :bow :pynd

    I am thinking about how cool it would be to make a custom CF adjustable windscreen like the TT Desierto... But I'm not sure I'm ready for a project like that after only reading all your posts. I think I will have to start with something more simple :scratch
    #25
  6. ebrabaek

    ebrabaek Long timer

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    :D:D...... It is that first time that you try this...... Then you are going to say..." wow.....it`s really that easy"..... As with the bash plate........the hard part is/was the foam build. Once the mold...or plug is build.... It is just a matter of laying up say 3 layers of cloth.....wetting it out with a brush. The reason this will be an easy project......is the fact that there will be little to no crazy bend.....sharp corners for the fabric to follow...... It will literally only take 30 minutes to lay op the composites. The fun part will be to construct the foam plug/mold....... To make something unique......Nice.... I have had alot of people ask through out the years if I give composite workshops.... Perhaps.... But you would have to come down here in the hot desert.......Could be fun though.....:thumb:thumb

    Erling
    #26
  7. ebrabaek

    ebrabaek Long timer

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    If any of you have followed my composite posts on Thumpertalk..... you know that I do make small .....hmmm..... should we say ...blunders. It is inevitable. When you make your own stuff.... you at some point are bound to forget something. Fact of life. What makes you succeed in the composite world....and the world in general.... is how you cope with such mistake. :D...
    Learn from it....and try not to let it de-rail your project. Well.... I`m not afraid to post when I forget something.....weather big or small. After the ride yesterday..... I took off the skidmax screen....to compare it with stock.... Guess what..... stock is just 1/4 inch narrower on the sides than the max.....And the gps was touching the screen.....:eek1:cry:cry. You might think....not a big deal since I`m making a new fairing....... rightfully so....But Just in case......that I don`t like the results of the fairing..... I need to be able to go back..... And never box yourself in.:evil. Of the plate went.....Added a little aluminum tape on the sides of the three mounts....and fill with fiber/epoxy mix.........hardened overnight....and ready for drilling of new holes.....
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    So.....all in all.....The important part here to learn.....One day.....could be your first projects as well..... It`s gonna happen...... Step back......take a look....and focus on how to fix it.......:thumb:thumb

    Erling
    #27
  8. ebrabaek

    ebrabaek Long timer

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    Now now.....all better......Top is the old one......bottom the new mount.....
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    Me thinks foam is in today......:thumb:thumb

    Erling
    #28
  9. ebrabaek

    ebrabaek Long timer

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    #29
  10. ebrabaek

    ebrabaek Long timer

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    Soooo... the foam came in today.......Actually yesterday....but no time until today. I started to make the front part of the shield...... Methodically cutting a 5 deg. angle every 2 inches.....to match the mounts.......
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    Then I though...... It`s Friday.......labor day weekend..... I think that means.....Less labor day.....Well....to me it is........So I thought....I`m gonna cheat a little. Rather than pegllefadut with this all day...... I chose to merely copy the mounting pattern from one of the other shields I had laying around.... Yes.... I have 3...in the quest for the holy grail. Remember..... In direct opposition to the D3....( No offense meant here).... They are using plastic....and therefore have to utilize a frame...in this case from mild steel.... Whereas this one is from CF.....where no frame is needed. The CF itself is the exoskeleton. So in short....two layers extra for the mount and we are good to go.......Other shield prepped...for cast with wax....and release agent......
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    Then 2 layers of the workhorse...5.7 oz 2x2 twill.......polymerproducts....max-clr/hp epoxy. Now drying....while I get to the top piece.....
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    Note the curvature........Again.... this is a very rough cut.....and most likely will be trimmed. Another thing here...... I`m not sure if I will like it..... As with any builds from the bottom up...... Unless you are a designer, and have access to cad`s.......etc.... It is really hard for me to visualize the shape until I build it. Plus....all people don`t share the same taste.....Wheras I think it looks cool....others might laugh....or better yet....dump the coffee in your keyboard. Angles are still a variable.... and until I mate the two halves..... Well....shall we just say.....This is the fun part......:thumb:thumb

    Erling
    #30
  11. jaycommando

    jaycommando Been here awhile

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    If you don't like it and it looks good I'll Buy it for Cost plus your estimation of labour...
    Nothing like good craftsmanship witnessed and recommended!
    you have a talent
    #31
  12. MSH

    MSH The Salt

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    I had him at hello. Buzz off.
    #32
  13. ebrabaek

    ebrabaek Long timer

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    :bow:bow....... So far I like it........:D

    :thumb:thumb

    Erling
    #33
  14. ebrabaek

    ebrabaek Long timer

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    :lol3:lol3....

    :thumb:thumb

    Erling
    #34
  15. ebrabaek

    ebrabaek Long timer

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    Sorry...... But I won`t be working on the project until after the 9`th of sept.
    I`m going to socal beginning tomorrow. I`l pick it up again when I get home....:thumb:thumb

    Erling
    #35
  16. HighTechCoonass

    HighTechCoonass Living the Dream....

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    Cant wait!!!!! Excellent work!!!:clap
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  17. GSranger

    GSranger blacksheep

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    :lurk :lurk :lurk
    #37
  18. ebrabaek

    ebrabaek Long timer

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    Back from socal yesterday......On with it we go......There are really two ways you can do this. You need to build the mold.......But the difference is.....One method..... You take the mold on and off fitting each piece.......and so forth.....You can then lay the mold on the table, and layup the composites...... That method is nice....because you can work at a workstation....sipping whatever you want. Main two drawbacks with that method is Mold is wobbly, and might shift during layup.....and as you design as you go along....one can loose track of how you want it to look.
    The other way is simply to cover the bike sort of like when you paint a room.... Then you glue up each piece at a time......Mold stays on the bike during construction. Pluses are rigid mold, since you are using the bike as support.....Second.... It is easy to change design as you go along......Bad....could make a mess with drips on the bike, and the cloth could sag when you wet it in. I used the first method when I build the CF skid plate.... And the second method with the fairing. It just depends on what you would like..... Hmm....Tue. thur.`s....method one.....wed.....fri...`s....number 2......:D:D.
    The you get the Styrofoam....Pick a point and begin.......
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    Note the foam being added to the left side...... Right ( picture) side still need to have foam added......
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    Then you cut corners......edges....sand to your liking......
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    There will always be voids in the foam...... You can fill it with what ever you can find...... Clay.....booger....Pilfer your kiddoes playdough..... Or I just happened to have some " clay epoxy" left....... Just fill in the gaps...
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    Then onto a few layers of release agent.......
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    Then use an old sheet of fabric.... to get the rough cut that you can use as a template cutting the carbon fiber.....
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    Then I only had enough CF for two layers........Waiting on ups on Tuesday.....
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    I mixed 228 grams of resin......(total weight).....And with the importance of getting the fabric right....... I would not recommend more than two layers at a time.....Well....at least in the hot desert.... as the setting time is reduced.
    A few things to mention for your consideration...... The fairing you build......is your own idea. The design is your own, and therefore taste is often very different from person to person. Byt your high ehhhh...middle school sculpting days will be tested here...... If you can build a mold.....then the layup is really the easy part. Since I am sort of designing as I go along.....plastic screen in mind...... It is hard to imagine the final product until the end...... And one of the neat things with the composites......is you can always remove material......but it`s harder to add it. Keeping that in mind...... I made the fairing a little big...... And plan on cutting it to shape when I finish two more layers, and have time to play with the shields. It is a little wider than I would have liked......But I have no choice....since I have the dashboard widened with the gps layout.
    Until Tuesday.....:thumb:thumb

    Erling
    #38
  19. MSH

    MSH The Salt

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    Till Tuesday nothing! I want more now! :-). Looks awesome. Did you make me one?:eek1 :evil
    #39
  20. ebrabaek

    ebrabaek Long timer

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    I know...I know.....:lol3.... Have`nt even made myself one yet......:D:D..... Tell you what..... We can meet in Moab.......I`l help you make one......Nothing like parking lot compositing......:D:D....
    :thumb:thumb

    Erling
    #40