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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    Thats what she said.
    #41
  2. ebrabaek

    ebrabaek Long timer

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    :lol3:lol3....
    :thumb:thumb

    Erling
    #42
  3. ebrabaek

    ebrabaek Long timer

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    So in anticipation of the ups truck arriving with the CF today...... I took off the fairing...... And cleaned up the bike.
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    Put the fairing ( now two layers of cf+ foam pieces).....and made a nice work stand....... Cleaned the edges a little, so the next 3 layers will conform nicely......
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    It is almost impossible to NOT bend the edges....corners of the wet cf cloth when they rest on the bike ( or any piece) It is better to have the wet cf cloth hang over about 1 inch all around, so not to9 have any sharp bends.
    I am hoping to add the 3 layers tonight, so I can begin the most fun part tomorrow...... The shaping. But... Tonight is movie night, and I just finished calibrating our new processor....... So Prince of Persia will sound awesome........ Until then ......:freaky

    :thumb:thumb

    Erling
    #43
  4. ebrabaek

    ebrabaek Long timer

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    Today was sanding day......:D... Even though you use release agent on the foam...... It still sticks. That is mostly in part to the contours. If you did not use it.... The resin would penetrate by far deeper.
    Fairing was cut to it`s rough dimensions....... Then sanded front and back. You don`t have to sand the front.... But from a design point, I find it better to design....ie. cut...reform.... the CF pieces when they don`t stare you straight in your face with the extreme glossy surface. The inside had to go..... Looked like.....styropoxyfiber.....:lol3:lol3. Here it is before the trimming.....
    I know ...I know.... Way big.......
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    The fit came out awesome.... The bottom brackets line up great.... And I just need to make 1/4 inch spacers ( Like I did on the skid plate mounts) on the other 4 holes..... That represent the void created by the foam removal...
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    All in all.... even though it`s a bit bigger than I`d hoped.....( no way around it due to my redesigned cockpit layout with the gps) I am now leaning towards using the stock shield. I personally really like that design, and with the fairing giving it a head start in height.... I think they will comment each other nicely.......:thumb:thumb

    Erling
    #44
  5. MSH

    MSH The Salt

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    Let me know when mine is ready! :thumb
    #45
  6. HighTechCoonass

    HighTechCoonass Living the Dream....

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    Just trimming your unit to match the factory shield? ..................Just a little rounding and trimming the top would be good I am thinking???
    #46
  7. ebrabaek

    ebrabaek Long timer

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    Exactly my thoughts......:thumb:thumb

    Erling
    #47
  8. ebrabaek

    ebrabaek Long timer

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    Today is very exiting........ I get to cut it into something I like......or not.:rofl...... As mentioned earlier......A project like this with the " design as you go along"..... You want to make it bigger....then trim as needed. I have been longing for that day.......since I thought that this fairing is big enough for both of my enduro`s.:D.... First.... I had to build up the mounts, since I did not like the flatter contour of the bracket pattern. As with the bash guard.....aluminum foil was used to create the containment......
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    Then filled with a fiber/epoxy mixture.....
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    Then.....after those were filed to my liking with the nuclear dentist tool...( dremel)... The fairing was mounted up..... And the masking for the proposed lines could begin.....
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    I then cut it with a 16 tpi hacksaw........ Trying to control this awkward piece on the band saw would spell disaster. Two things I have come to realize......
    1. I really like the rough battle look of matte finish.... And this is even before seeing the beautiful CF pattern.
    2. You can mask the general big shape of an object by alter the curves......:lol3:D:rofl:rofl:clap:clap..... Sounds like taken out of " What woman want"...starring Mel Gibson... But really in this build it really applied to the piece itself.
    After the cut.......
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    And on the bike... Mind you... from the angle on the first shot ...it looks like the top is square... It is not....
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    Then the stock shield was trimmed to sort of fit the fairing.......In the down position.....
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    In the up position........
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    The fairing height and with is very close to the stock screen.... So I need to get some longer m5`s to hold the shield in place..... And then drive it with the fairing only.....before mounting the screen....... Until then.....:thumb:thumb
    #48
  9. ebrabaek

    ebrabaek Long timer

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    All mounted up for the first test ride....... I am really starting to like it......
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    Report back in a few....after the ride......
    :thumb:thumb

    Erling
    #49
  10. ebrabaek

    ebrabaek Long timer

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    I could just leave it like this......... It is very tolerable.... Although not a completely calm experience...... Very little head and neck buffeting. Without being in a widn tunnel ....it is very hard to say. But it has by far less annoying turbulence that the stock shield. I just went out for another ride with the cut piece in the high position...... And not sure I like that idea. Although calmer around the head...... my head is now in the small areas of turbulence.....but the stocker`s cool cut angles might not break the wind in a nice matter..... Time to put the skidmax under the knife. That leaves me with a Ztechnik tall to fall back on..... Nahhhhhh..... the alien head will never get back on my gs....:thumb:thumb

    Erling
    #50
  11. MSH

    MSH The Salt

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    [​IMG]

    Nice! Are you going to fashion some of those little robot brackets to it? Great idea.
    #51
  12. ebrabaek

    ebrabaek Long timer

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    Yeppers.......
    Scrounged up some nylon and Aluminum spacers.... It will slide up and Down 6 inches.:thumb:thumb
    Erling
    #52
  13. ebrabaek

    ebrabaek Long timer

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    I used an old trick I found years back...... Since I am really starting to like this more and more by itself..... (without the screen).... I... instead of a top coat of epoxy to seal it...... I just rubbed the epoxy in the fairing...... Just like you would rub oil into a piece of furniture..... Wiping off the excess epoxy off. That will create a almost satin surface..... And I think....to me at least......:D ... It looks awesome like that. It is drying right now...... Pics to follow in the morning......:thumb:thumb

    Erling
    #53
  14. ebrabaek

    ebrabaek Long timer

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    Ok.....here it is......
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    Here you can see the finish....kind of satin...... This is with the method mentioned above....... Without any finish added......
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    Video coming shortly.....:thumb:thumb

    Erling


    Edit: Video added........ Click on the thumb below....
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    #54
  15. space

    space a.k.a. Jake

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    :thumb Very nice. You gonna toss on a coat of UV protection too?
    #55
  16. ebrabaek

    ebrabaek Long timer

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    Yeppers....... After I decide whether or not to mount a screen on it....It`l get a coat of uv protection.....That will then get buffed to mimic the current finish....which I really like...:thumb:thumb

    Erling
    #56
  17. ebrabaek

    ebrabaek Long timer

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    Time to cut the screen...... Used a 2 amp dremmel......router bit....and went for it..... Poor little thing...... I had to cool the little thing 4 times with compressed air........:lol3:lol3 Measeured, and taped.....200mm...
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    Ready....set....go.....
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    After the first side is done...... Note.... Went in two stages to get the with...
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    Arrrrggggggggggggg....... The toes........again.....:rofl:rofl

    Ok...... I need your help....... I am going bonkers deciding weather or not to put up the screen. I thought as I go along with the groove cutting....etc.... The solution will present itself. The skinny...... I totally love the look of the fairing only. Every time I look at it from any side....but mostly riding....he-he.....
    I could just leave it.... The wind breaks just under my neck....and leaves my head in mostly clean air. When I rode with the stocker...( about same size)... Although the wind had diminished.... There were the turbulence....just a little....never the less..... It was there. The other side......I think the screen breaks the nice lines of the screen........Wadayathink??????:ear:ear

    In the down possition.....
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    In the up position......
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    Pleeeeeeeeeeeeeeeeeeeeezzzzze....:thumb:thumb

    Erling
    #57
  18. Ducksbane

    Ducksbane Quaaack!!!

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    Looks great :thumb

    Why don't you tape it securely in the up position and try it? Then maybe try half up. Then you will know if it's worth potentially ruining your work of art for functional benifits.

    Or you could be like apple and just go for art for arts sake!

    :hide
    #58
  19. ebrabaek

    ebrabaek Long timer

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    Good idea...... As I tried it with the stock screen in the high position... I think I need to explore that with more saddle time...... It is hard to decide after a 15 minute ride...... Summer fast approaching in Aus...??? Our desert is cooling nicely.....:thumb:thumb

    Erling
    #59
  20. Ducksbane

    Ducksbane Quaaack!!!

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    I think its supposed to be spring around here (New England region of NSW) but it started off with 0 degrees Celcius and a big frost this morning :vardy ... can't be long now!
    #60