How to wrap your F800GS in Carbon Fiber......

Discussion in 'Parallel Universe' started by ebrabaek, Jul 26, 2010.

  1. ricohman

    ricohman Long timer

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    Is the CF part larger than the original since its not actually a mold?
    #21
  2. ebrabaek

    ebrabaek Long timer

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    Yes...by 1 1/4mm.......In this application...not an issue.
    :thumb:thumb

    Erling
    #22
  3. ebrabaek

    ebrabaek Long timer

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    Finished.......After 1 hr of finish sanding........It was finally ready to coat with a of the shelf automotive spray lacquer, with a uv inhibitor......
    [​IMG]


    After two layers of lacquer......
    [​IMG]


    And finally .... next to original piece......
    [​IMG]

    In a few minutes.....on the bike......
    :thumb:thumb

    Erling
    #23
  4. ebrabaek

    ebrabaek Long timer

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    Finished......and on the bike.......
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    So all in all.....4.5 to 5 hrs of labor......... It is an easy project for the first timers........material under US$50........ In closing..... This piece will be build upon in a few weeks. The part I wanted to promote.....is how easy this particular project is/was. Even for the total beginner......double the labor....and you still only have 10 hrs in it. Next project is a CF/Kevlar honeycomb skidplate.....But that`s another story..... Post up questions....there are many material questions....I`m sure.....I`m here to help. Off for a test ride........:thumb:thumb

    Erling
    #24
    zero war likes this.
  5. OverlandHank

    OverlandHank Loves to Farkel

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    Very Nice work!
    #25
  6. WoodWorks

    WoodWorks House Ape

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    Not that I expect it to be significant, but have you had a chance to see of there's any weight difference between yours and the OEM part?

    David
    #26
  7. CrazyMike

    CrazyMike ***42***

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    David,
    You missed a spot. Check post #20 (the green text).




    Ebrabaek,
    Very cool...keep up the good work and keep showing us!!! :clap
    #27
  8. LewisNClark

    LewisNClark Long timer Supporter

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    Very interesting project – thanks for taking the time and harrassment..:D

    Questions:
    1)Could you cut and paste a corrected list of supplies I made below? (know some of it is wrong, or duplicated)
    2)Could you make a modifed list for making a bash plate ? (ie. Stronger material)
    3)How high a risk of ruining the OEM plastics with making the mold ?
    4)Wouldn’t the skid/bash plate be a safe first project since if you screw it up a little and can’t see, it your safe.

    (Could you check my list of supplies and cut and paste corrected list for anyone else's interest).

    Supplies:
    Silmer 249 – Polyester (USComposites)
    Epoxy (Brand ?)
    Resin (Brand ?)
    Automotive Spray Lacquer (with UV inhibitor)
    Twill 5.7 oz Cloth (Brand?)
    Sand paper – 80 grit (rough sanding)
    Sand paper – 220 grit (finish sanding)
    Black Electric Tape
    Plastic Cups for mixing
    Wax (with high carnuba wax) (is that just car wax?)
    Parafilm (nold release spray?)
    Resin with wax - ???
    Surfacing wax Modifier – C
     
    Tools:
    Dremmel
    Paint sprayer/compressor (needed ?)
    Brushes (?)
     

    #28
  9. ebrabaek

    ebrabaek Long timer

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    There are several places to get the resin etc.... But above are the links to where I get them... Don`t mind the fleabay. That is just a cheaper way to get it...Than their main website. They know their stuff.
    :thumb:thumb

    Erling
    #29
  10. WoodWorks

    WoodWorks House Ape

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    D'oh! Thanks Mike. :shog

    David
    #30
  11. LewisNClark

    LewisNClark Long timer Supporter

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    thanks for taking the time to respond.:clap

    #31
  12. ebrabaek

    ebrabaek Long timer

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    Your quite welcome. The works of composites, can be quite intimidating, and so many people forgo making this a hobby. The pieces one can buy cost an arm and a leg due to the labor involved, and really...the part I enjoy the most is not the looks....really... It looks great, but in all honesty... It`s the fabbing, of new unique items that I see this for. Like the first picture of my DRZ.... The front faring..... The rear integrated tail light..... The exhaust pipe...... Your imagination really is the limit... Well sort of.:D.... Hopefully I can lure a few souls to the dark side.......:beer
    :thumb:thumb

    Erling
    #32
  13. LewisNClark

    LewisNClark Long timer Supporter

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    you wrote:

    This is the simplest way to replicate a piece...... You prep it....lay a few layers of composite over it....let dry....and you now have a copy.....although 1-2mm larger....and lots of sanding and buffeting....nevertheless.....a simple copy. At a later stage....I will cast a mold....and replicate from that....but for now.....Let`s keep it simple.

    Then you remove the extra plastic

    Confused as to which chemical(s) are used to "lay a few layers of composite over it". Is that a plastic like sheet or the chemical (which?) is painted on with a brush. Can't tell from your pictures.

    I've done a lot of fiberglass but never made a mold.
    #33
  14. ebrabaek

    ebrabaek Long timer

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    No worries........ I referred to the plastic to be copied..( yellow in my case cover)........ You have to create a barrier between the piece to be copied and the CF/resin mix...... Two major ways to accomplish this are several layers of wax.......( creates a friction less surface that the resin cannot bond to) or a synthetic barrier ( Spray or brush on liquid that dries to a micro fine membrane...like parafilm.)

    Piece to be copied, after wax.......
    [​IMG]


    Same piece, after wax......and parafilm.......Note the duller finish, after the coating...
    [​IMG]

    Hope this clears it.... If not....ask again......:thumb:thumb

    Erling
    #34
  15. TastyPants

    TastyPants Harasshole

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    Great thread ebrabaek! I have a limited workspace but love stuff like this. Looks doable with my tools and garage :)

    Looking forward to your bashplate solution. Sounds like a fun project.

    Are you planning to do the entire bike? I'd be curious to know the weight difference after all the plastics are done.

    PS- in your post about the weight you mentioned that two pieces of CF would be more than enough, does that mean we can go one piece for an even lighter just enough?? JK .:lol3
    #35
  16. SlowRide13

    SlowRide13 Veteran n00b

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    Thank you for taking the time to share this... Please keep it coming!
    #36
  17. ebrabaek

    ebrabaek Long timer

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    Thanks.....Yeppers... The bash plate will be fun, and stronger than any aluminum plate available. As far as the whole bike...... I don`t think so. I can only have one Darth Vador......:D, but if I did.... I`d perhaps save 10-15 lbs......I`d never do it for the savings.....I could loose a few pounds myself....:rofl..... Yep.....two pieces or layers would be strong enough... ( 5.7 oz weight) On average...you would see a between 35-50% reduction from plastic....which is heavy in comparisson. It depends on the torsional stiffness requirement....balanced with impact resistance requirement.
    :thumb:thumb

    Erling
    #37
  18. ebrabaek

    ebrabaek Long timer

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    Yeppers.......
    :thumb:thumb

    Erling
    #38
  19. Mac

    Mac Long timer

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    The hybrid carbon/kevlar stuff looks pretty neat. I bet the orange/black stuff would work and look great on a KTM.

    http://uscomposites.com/hybrids.html

    [​IMG]


    I think I just found a winter project, or three...
    #39
  20. ebrabaek

    ebrabaek Long timer

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    Before you order the hybrid.......call and ask them for a little sample..... They are usually good about that. That way you can do a accurate comparison. I tried the yellow....But did not match the bumble bee. It might on the ktm though.......:thumb:thumb

    Erling
    #40