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

Discussion in 'Parallel Universe' started by ebrabaek, Jan 8, 2011.

  1. beechum1

    beechum1 Dandole Gas al Burro

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    :lurk
    #81
  2. ebrabaek

    ebrabaek Long timer

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    So in order to satisfy your popcorn munchers.....:D... box was brushed with resin......
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    Then a 44x 15 inch piece of CF was cut....so to overlay all but the top (pictured) This final layer is purely cosmetic.....there are already plenty of strength in there.
    Wrapped it around....and had one seam in the back (inside) and a small on in the top left..... These will of course be sanded smooth...
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    In the oven for initial cure..... a few hrs at 90-100 deg.F. If you go straight to post cure @250..... The fabric has not set....and you will risk the CF becoming dynamic..( moving).
    [​IMG]

    Onward we go with the other box......:thumb:thumb
    #82
  3. ebrabaek

    ebrabaek Long timer

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    A few notes...... It does not matter how much experience you have...... The second piece will always be better than the first one......:rofl:wink:..... Ohh... well... not really kidding here. As the first box came together..... I was not comfy with the patterns that was laid down..... thus stressing the material more than I would have liked...... No biggie..... You just stop before the last layer.....let it cure..... then sand it smooth...... But obviously it would be great if one could lay`em all wet in the first go. Well as history repeats itself with me..... That was the case with the second box. With the knowledge of the first go..... It all went down great in one take....and even still looks better than the first one..... Here is the second with all layers on......
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    There is still the seam in the back....and a very small one in the top left on the second pic..... but again...they will be sanded out......

    :thumb:thumb

    Erling
    #83
  4. HighTechCoonass

    HighTechCoonass Living the Dream....

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    How many hours of work and how much are the materials?
    #84
  5. ebrabaek

    ebrabaek Long timer

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    It`s still early in the project...... But I think the epoxy and Kevlar+ Carbon Fiber about $200 Out of that...there are several cut CF and Kevlar to be used for the next project....due to funky patterns..... Add perhaps $35 in hardware.... I`m expecting to be on the right side of $300 for both.... As for the labor..... So far....about 10 hrs..... give and take a few.... It`s time consuming...... And that`s where it`l pay off....if you don`t mind spending a little time sipping liquids in the garage......:thumb:thumb

    Erling
    #85
  6. ebrabaek

    ebrabaek Long timer

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    It`s great to have friends....:D:D

    :thumb:thumb

    Erling
    #86
  7. HighTechCoonass

    HighTechCoonass Living the Dream....

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    Erling you are a master!:clap:clap:clap:clap:clap
    #87
  8. ebrabaek

    ebrabaek Long timer

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    Thank you sir.....:bow

    :thumb:thumb

    Erling
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  9. JustKip

    JustKip Long timer

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    I rarely look over here in the parallel twins forum, cuz I don't have one.
    But I gotta say;

    GREAT work, Erling!
    #89
  10. ebrabaek

    ebrabaek Long timer

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    Here are the parallel twins......:D..... Cured...and ready for the next step. Tomorrow....They will be sanded......then de-molded......inside prepped for honeycomb.....and a few strategic placed extra layers of CF for the mounting of the water and fuel 1 gallon Rotopax`s...... And then final layer of Kevlar on the inside.....
    [​IMG]
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    Until then........:thumb:thumb

    Erling
    #90
  11. ebrabaek

    ebrabaek Long timer

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    Thanks..... They will fit any bike......:evil:evil:D

    :thumb:thumb

    Erling
    #91
  12. TheJoker

    TheJoker Adventurer

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    Very very nice, Erling!

    Also very pleased to see the Fiskars scissors featured. I grew up 25mins from the factory and my friend's wife works at the factory now. :clap Best scissors you can get, IMO. :evil

    Now where's my popcorn machine, I've ran out.. :lurk
    #92
  13. ebrabaek

    ebrabaek Long timer

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    Absolutely.....:thumb..... I have tried so many scissors over the years...... And there are some great Kevlar shears out there, but they are very expensive.....and need to be sharpened after a little while...... Fiskars have been part of my family since I was a kid. Regarded very high in Denmark, as well as in other parts of the world. And for $US10 for this model....... It is incredible. Let alone the fact it will cut Kevlar.......:thumb:thumb

    Erling
    #93
  14. TowPro

    TowPro Single Track Geezer

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    I have some questions about the steps.
    I tried to take these steps right out of your picture post.

    1) Brush a layer of epoxy on the plug.
    2) lay your first layer.
    3) then you show "lay up one layer of Kevlar".

    Before 2 and 3 do I brush on another layer of epoxy?

    4) Next you say "then the final layer".
    Is 4 another layer of epoxy, or kevlar?

    5)Then into the oven.
    #94
  15. beechum1

    beechum1 Dandole Gas al Burro

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    6) do you squeegee the excess resin, or do you just "know"
    #95
  16. ebrabaek

    ebrabaek Long timer

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    This answer is for the 2 above posts. The method is the same regardless of the project..... First you brush or roll resin on the object.... In this case a foam plug..... You then lay down the fabric..... Thus wetting it from the inside rather than trying to push the resin through with the brush or roller. I like to massage the fabric with my hands as well. You then repeat the process with resin..... Then cloth..... Which ever many layers are required.... Or if this is the last layer.... Just leave the resin on top. I prefer using a foam roller rather than a brush..... When you put a little presure on it it effectively squeegee's the left over resin out.
    #96
  17. ebrabaek

    ebrabaek Long timer

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    This is how it must feel...cleaning a cavity.......First the mold was broken off the stand....and cut along the edges...... Be ready for some elbow grease.... The same property`s that we enjoy with Kevlar..... Makes it a challenge to cut.....I use a high tpi metal blade....and sip plenty of espresso whilst at it....
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    Then from here on...its really up to you..... Spoon.....screwdriver.....dynamite....have at it....
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    A note here.... The red foam from the depot I used....is great holding up....it`s very hard.....and great for mold building..... But a pain to remove.... Whereas the Styrofoam is easy to remove....but dents easy... So I dug out the big tools......Dentistry anyone???
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    After a while....it`l look like this.....
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    Then you "melt" the remaining foam with acetone....and then sanding to rough up for the inside layer......
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    A very cool thing about the composites.... You can just add strength in areas needed by additional ply`s....... So I marked where the aux tank mount need to be......
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    Ups......post getting long........
    #97
  18. ebrabaek

    ebrabaek Long timer

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    Then cut the fancy honeycomb material......:D
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    Then make sure you have all materials at hand before you mix the pox...... Honeycomb.....4 layers of CF....1 layer of Kevlar...:thumb

    [​IMG]

    Then you wet the area with epoxy..... then the cardboard.......place the cardboard...
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    Then all layers of composites.....wetting with epoxy in between layers....
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    Let that dry until it stays in place...... then onward with the other sides....etc....
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    Another note here....... To conform the composites over the cardboard..... you might need some weights...to hold it down....it just depends..... When it cures....or if you accelerates the cure like I do...by curing in the sun.... then air will expand....and sort of blow up the composites...... then use your imagination.....
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    By now....you have properly noticed you need to have a passion for this stuff to dive in a project like this..... Don`t let this discourage you..... Not kidding here....it takes time.... But you will be rewarded in the end.....and to me that is worth it all.......:thumb:thumb

    Erling
    #98
  19. The Griz

    The Griz Long timer Supporter

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    Wow. All I can say is AWESOME WORK. Looks amazing! :clap:freaky
    #99
  20. beechum1

    beechum1 Dandole Gas al Burro

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