Carbon/Kevlar rear luggage boxes.....It has begun....

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-HIG...247?pt=LH_DefaultDomain_0&hash=item483836807f

Regular epoxy.....
http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=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-S..._9?s=industrial&ie=UTF8&qid=1306195150&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-5yc...splay?langId=-1&storeId=10051&catalogId=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-5yc...splay?langId=-1&storeId=10051&catalogId=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

You may be waiting a long time... it seems that cold is everywhere.

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.

He-he.... Except in the desert Southwest.....The highs should be close to 60 today.......ahhhhhhhhh.....



Erling

Perhaps your right......


Erling

Do it in your house.

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

Good start

I look forward to following this thread! Carbon fiber/Kevlar boxes? Hell yeah, durable as hell and light!!

I was wondering when you'd get around to making a set of CF luggage cases....

Please..... carry on.

I had a feeling you would like this idea Griz.....



Erling

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


Erling

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

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?

Just ordered one 1 gal rotopax fuel, and one 1 gal rotopax water can....they will mount one behind each case.........



Erling

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

Can't wait to see the results. Perhaps I'll need to replace my Vario's.

David

I was hoping we wouldn't be seeing toes in this build.

At least there is no doubt this time........ Eliminating the guesswork unlike last time......dang..... well......it`s not over yet......



Erling

So the rear rack re shaping began..... These boxes can be made to suit any mounting arraignments.... Another great thing about making them yourself....
In my case I had made a rear rack from 1/2 SS about 18 months ago. It was made for a set of Ortlieb QR bags....and the rack had to be modded slightly to accommodate the new boxes. For one.... the down tubes were angled outward to keep the bags away from the hot exhaust......


Off the bike.......


The new bags will be mounted about 1 inch from the pipe..... They will not be prone to heat stress, since I will be using a high temperature epoxy.....rated up to about 400 F. I was torn about moving them closer ( boxes that is).... but the primary usage for this bike...needs to accommodate a wide rear rack to "throw" things on. That is/was not negotiable. Because of this...they will have to be out wide. So after some cutting....and re-bending..... The down tubes were angled correctly...... Welding began....and after 30 minutes.....I ran out of SS wire......arrrrgggggg.... Thanks goodness for ACE.... only HWS to have SS mig wire.... Onward we went.... have a laugh.... My welding sucks...but I`m lethal with a grinder..... Perhaps the little 110V mig was under a lot of stress...... But as long as it will hold up....and it will.....



Then just for the visual element.... The boxes were taped on..... so the shaping can begin.......





Let the shaping begin........



Erling

:eek1

does this foam make my ass big?

Looks like you should be able to use the "exhaust" area on the right side for a fuel tank. Looks like you located them further back than the varios. Does the front brace interfere with the passanger's legs? 37" width is pretty good considering the competition.

David