View Full Version : Carbon Fiber Fabrication.
Well I have decided to go ahead and take on the project of carbon fiber fabrication.
Today I bought mold making materials, fiberglass fiber (practice before using costly carbon fibers) A vacuum kit, several epoxies, plaster, and small tools.
I still have plenty to add....I will be working with my father who has experience in Aerospace carbon fiber applications to fine tune all the small important details. Heres what I know.
I will be using Epoxy resin, not Ester resin
I will be creating continuous weave tubing (seamless)
I will be attempting intake piping, exterior pieces, interior pieces, and possibly exhaust in the future.
All products will be cured in a vacuum at a minimum of 15 PSI. (based on my kit)
several thicknesses/patterns of fiber will be used
I am open to ideas for pieces, and most likely will make some license plate frames as an introduction (do to ease of fabrication).
I am mainly doing this for fun, and to express my inner creativity. I am also interested in doing enclosures for speakers, subwoofers, and other electronics...
I will update as I move along for those interested in my progress!
Johnmadd
05-24-2011, 08:06 PM
Very cool and ambitious. I would be willing to sport a sample piece for you to advertise a pic with. ;-)
Very cool and ambitious. I would be willing to sport a sample piece for you to advertise a pic with. ;-)
Haha sounds good, I'l make you a carbon fiber hat ;)
billschusteriv
05-24-2011, 08:24 PM
Hehe...
Very cool Dean! Looking forward to updates and pics!
Johnmadd
05-24-2011, 08:32 PM
Haha sounds good, I'l make you a carbon fiber hood ;)
Fixed, thanks Dean.
Fixed, thanks Dean.
HAHA smooth! And you know, when I start getting into larger parts, I'l be sure to let you know. I'm pretty excited already however. The possibilities are endless...one peice I may make is a carbon fiber shifter surround...I have to get ahold of one I can take the plastic off of however for use of the clips
Made a fiberglass part today to test a method of fabrication called "lost foam" unfortunately the fiber glass resin I had laying around was terribly old and lumpy, and cured very quick leaving me little time to work...I also vaccumed without peel ply or an absorbent blanket for excess resin. Most likely this part will come out pretty ugly, but it only took about two hours start to finish. I'l update with pics.
danewilson77
05-25-2011, 05:25 PM
Made a fiberglass part today to test a method of fabrication called "lost foam" unfortunately the fiber glass resin I had laying around was terribly old and lumpy, and cured very quick leaving me little time to work...I also vaccumed without peel ply or an absorbent blanket for excess resin. Most likely this part will come out pretty ugly, but it only took about two hours start to finish. I'l update with pics.
What was the part? Or is this a teaser thread?
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Well, no teaser . Although this weekend I may have a few. This was really a learning step. Cheap fiberglass using a type of foam as a mold. I have learned more about the resin , the type of foam (this foam did not work as I had wished, so I will be changing to a different type) and how the fiber can be conformed to different angles and sizes. As I said, and predicted , it is very ugly and was a learning tool..my objective was to make a part (no use, just a shape containing different angles) and see what the limits are. Peel ply and absorbent material inside of the vacuum process are a must for aesthetics. I got the results I was looking for to do more homework/research and obtain the tools and materials needed for actual parts. I should be able to present a fiber glass part this weekend from the e46, most likely the intake tube running from the grill snorkel to the air box. Small and simple. I will also try to attempt tradition lay mold techniques and replicate something like a mirror cover. Stay tuned. :) . This was my ugly ducking, but I already obtained a lot of necessary knowledge!
danewilson77
05-26-2011, 04:22 AM
That's gorgeous!!!! How much? Are you willing to ship!!!!
billschusteriv
05-26-2011, 05:13 AM
Nice first work! Reminds me of the inlet hose to the airbox on the e30. :)
I sense a budding business on the horizon once you get your process down... and apparently Dane wants the first test piece... autographed too I bet...
That's gorgeous!!!! How much? Are you willing to ship!!!!
I can ship, due to it's rarity (one in existence) I will do 150 shipped. A bargain if I ever saw one. And as requested, it will be autographed. Should it be made out to dw, Dane, or Dane Wilson? :) haha
danewilson77
05-26-2011, 07:09 AM
DW77. What's your Paypal?
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johnrando
05-26-2011, 10:27 AM
Depending on price, a license plate frame and/or a diffuser would be good. John
DW77. What's your Paypal?
Droid + Tapatalk = FTW!
You can have it for FREE. that's how nice I am. This is grade a stuff were talking :)
Depending on price, a license plate frame and/or a diffuser would be good. John
Well I'l be attempting license plate frames soon. I'l let you know. I figure about one month until I am proficient enough to have stream lined the process.
Marcus-SanDiego
05-26-2011, 01:03 PM
You can have it for FREE. that's how nice I am. This is grade a stuff were talking :)
Dean, thanks for taking care of my lieutenant. Much appreciated, pal.
iPad. Tapatalk. Bi-winning.
Dean, thanks for taking care of my lieutenant. Much appreciated, pal.
iPad. Tapatalk. Bi-winning.
Of course boss. Always at your service
Marcus-SanDiego
05-26-2011, 01:10 PM
Of course boss. Always at your service
You guys really crack me up with the boss reference. :thumbup
iPad. Tapatalk. Bi-winning.
You guys really crack me up with the boss reference. :thumbup
iPad. Tapatalk. Bi-winning.
You know that it makes you all warm and fuzzy inside knowing how much respect we have for da boss! Admit it.
Marcus-SanDiego
05-26-2011, 01:21 PM
You know that it makes you all warm and fuzzy inside knowing how much respect we have for da boss! Admit it.
I know you guys respect me because I'm an old timer on the BMW forums. :biggrin Just respecting your elders.
But, really, I'm humbled by it. That's why I chuckle. I don't take myself seriously, so it's funny when you guys say it.
iPad. Tapatalk. Bi-winning.
I know you guys respect me because I'm an old timer on the BMW forums. :biggrin Just respecting your elders.
But, really, I'm humbled by it. That's why I chuckle. I don't take myself seriously, so it's funny when you guys say it.
iPad. Tapatalk. Bi-winning.
You better take yourself serious. You are the boss :). Haha
Alright, got more of a solid plan going now. Ordering materials wednesday. Should have production prototypes beginning of next week or earlier.
Most likely to include-
License plate frame
Shift console surround
engine cover
Mirror cover
Some may be included, others may not. Will update with pictures.
Update: ordered over 300 dollars in materials. Plenty to get started with molds and parts. Also developed my own vacuum bagging system for under 60 bucks. 21 inches of mercury air tight sealed allowing for vacuum curing. This will deliver added strength to weight ratio, and a true gloss finish without polishing or clearcoat. I will be using the same methods as aerospace composite manufacturers. I also got two 3 inch binders of knowledge thanks to my dad who works for the FAA (federal aviation administration) on composite fabrication processes, structural information, and repairs. Hope to start production by middle of next week. Materials won't arrive until early next week. Stay tuned!
danewilson77
06-01-2011, 07:35 PM
I want splitters....that will fit my car.
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johnrando
06-01-2011, 07:36 PM
Alright, got more of a solid plan going now. Ordering materials wednesday. Should have production prototypes beginning of next week or earlier.
Most likely to include-
License plate frame
Shift console surround
engine cover
Mirror cover
Some may be included, others may not. Will update with pictures.
One suggestion for the license plate frame... make the bottom big enough to hold the "zhpmafia.com" stickers.
I want splitters....that will fit my car.
Droid + Tapatalk = FTW!
Oh believe me, they are definitely on my to do list. I have considered fabricating my own from scratch, although I may start with another manufacturers and modify for a better fit. I'l have to see how things go. Maybe I can get a hold of some BMW performance splitters and replicate the fit on those. They are just pricey..
danewilson77
06-01-2011, 07:39 PM
I'm down for a set of these. Do I hear group buy?
Droid + Tapatalk = FTW!
One suggestion for the license plate frame... make the bottom big enough to hold the "zhpmafia.com" stickers.
Hmm... That or I can include ZHP mafia in lowered lettering imprinted in the carbon fiber :) it wouldn't be super noticeable however..
I'm down for a set of these. Do I hear group buy?
Droid + Tapatalk = FTW!
Let me mess around with molds and fabrication before I commit to something if I cannot pull through! I'm sure I'l get there though. I'm very excited to start this and I can see myself becoming very passionate with my work. I talked to marcus a bit about being a sponsor on here and before I do all that I need to plan out a more strategic business approach to things..this will all follow once I can start getting further along.
danewilson77
06-02-2011, 05:54 AM
Let me mess around with molds and fabrication before I commit to something if I cannot pull through! I'm sure I'l get there though. I'm very excited to start this and I can see myself becoming very passionate with my work. I talked to marcus a bit about being a sponsor on here and before I do all that I need to plan out a more strategic business approach to things..this will all follow once I can start getting further along.
Did I mention I was in for some splitters?
Droid + Tapatalk = FTW!
danewilson77
06-02-2011, 10:10 AM
OK.....just scheckin...lol
M3TA5IN
06-02-2011, 10:31 AM
This is interesting, something I would like to learn.
If you get good let me know and you can make me a CSL trunk :p
I had an idea for a peice you would add on much like a spoiler, to get the same shape as the csl without replacing your trunk. Obviously this wouldn't decrease weight as the csl does, purely for aesthetics. Just something I was thinking about the other night.. I'm afraid it wouldnt come out like I want though..
danewilson77
06-02-2011, 05:55 PM
I want one of these too.
As long as you spread the word of my products :) . I can't wait to start on the license plate frames (ZHP mafia edition) . Hopefully I can show you guys some good work.
Quick sketch. Receding seam from edges in to hide from a side view. rear body line of trunk will be replicated by lip of spoiler. Getting excited at this point.
Johnmadd
06-02-2011, 08:51 PM
Alright, good sketch. You must have an eye for this kind of stuff, good work Dean.
Haha thanks, more credit than I deserve for it. 3 years of architectural drafting should have yielded better results, but it was quick to get the idea across. Hopefully it doesn't get stolen :p
Picking up all materials tomorrow around 1600. I'l post some pictures for you guys.
danewilson77
06-06-2011, 02:32 AM
Another teaser thread huh? I am crowning you king of teaser threads...hehe. can't wait brutha. Hope production goes well for you.
Droid + Tapatalk = FTW!
Haha thank you for crowning me sir :)
Marcus-SanDiego
06-06-2011, 07:56 AM
And that's saying a lot coming from the emperor (Dane) of teaser threads.
danewilson77
06-06-2011, 08:32 AM
And that's saying a lot coming from the emperor (Dane) of teaser threads.
Emperor.....mmm.....I like.
Droid + Tapatalk = FTW!
billschusteriv
06-06-2011, 10:47 AM
Good thread. I like seeing the progress!
Yep, should be fun! Im excited to see the manufacturer as well. They do aerospace components, and I might get to take a little look around at what they do. I got a little extra motivation now to push me harder through the process. I am starting flight lessons soon, so I can definitely use the extra dolla dolla.
http://tapatalk.com/mu/4cdc428a-d002-4a9c.jpg
danewilson77
06-07-2011, 05:31 PM
http://tapatalk.com/mu/4cdc428a-d002-4a9c.jpg
Ok.....nice. let's see da finis....
Droid + Tapatalk = FTW!
This is just the mold. I'l show results tomorrow when the inner portion is dry. Haha. Long process. Very intricate... Lemme tell ya.
danewilson77
06-07-2011, 05:42 PM
This is just the mold. I'l show results tomorrow when the inner portion is dry. Haha. Long process. Very intricate... Lemme tell ya.
Roger Dean. Respect the work brutha.
Droid + Tapatalk = FTW!
You bet! Oh and I want some stickers...I'l have to paypal you tonight
danewilson77
06-07-2011, 05:47 PM
You bet! Oh and I want some stickers...I'l have to paypal you tonight
Bring it.......hehe
Droid + Tapatalk = FTW!
By the time I get to it here on the west coast you might be off for the night, but message me the Paypal and I'l send the $$ and a message with what I want!
danewilson77
06-07-2011, 05:54 PM
By the time I get to it here on the west coast you might be off for the night, but message me the Paypal and I'l send the $$ and a message with what I want!
Copy.
Droid + Tapatalk = FTW!
http://tapatalk.com/mu/4cdc428a-05f9-92f7.jpg
danewilson77
06-08-2011, 03:07 AM
http://tapatalk.com/mu/4cdc428a-05f9-92f7.jpg
Yum. And the transformation continues..
Droid + Tapatalk = FTW!
Marcus-SanDiego
06-08-2011, 08:44 AM
http://tapatalk.com/mu/4cdc428a-05f9-92f7.jpg
Dean, nice work so far. I know exactly what that is. Excited.
johnrando
06-08-2011, 09:00 AM
Ah, I'm getting it now. Cool, can't wait!
Marcus-SanDiego
06-08-2011, 09:02 AM
^ :biggrin
Yep. ZHPMafia.com exclusive.
billschusteriv
06-08-2011, 09:52 AM
Very nice Dean. Appreciate photos of the progress and process. :thumbsup
Pretty good results from the mold. I'm remaking it to get a glossier finish. I have to polish the license frame to a high gloss before plugging into my mold in order to receive a high gloss female mold. This is necessary to obtain a high gloss product. I'm hoping to get the first one out by this weekend. Mold should be finished by this week.
Marcus-SanDiego
06-08-2011, 01:39 PM
Good stuff, Dean.
http://tapatalk.com/mu/4cdc428a-0b79-788a.jpg
First mold attempt. Not happy. Redoing as we speak.
Marcus-SanDiego
06-08-2011, 04:00 PM
Dean, I love your drive.
danewilson77
06-08-2011, 04:02 PM
Respect the work Dean....
Droid + Tapatalk = FTW!
billschusteriv
06-08-2011, 08:45 PM
Nice!
In the middle of sanding filler before primer and paint. This is the plug for my female mold. I'm taking as much time as needed and being as precise as possible so I can create a flawless mold. The part will only be as good as the mold.
http://tapatalk.com/mu/a6cd88ac-2285-bbdb.jpg
Marcus-SanDiego
06-09-2011, 12:01 PM
Plug on, Dean. Looking forward to the finished product.
2nd coat primer. http://tapatalk.com/mu/a6cd88ac-90d5-f6fb.jpg
Marcus-SanDiego
06-09-2011, 07:43 PM
Dean, coming along.
Crestwood1001
06-09-2011, 08:19 PM
Looking great!
danewilson77
06-09-2011, 08:23 PM
Looks really great.
Droid + Tapatalk = FTW!
thesixsins
06-15-2011, 09:19 PM
Damn! Sick project!
I was just thinking today how I wanted to design my own splitters.
Keep us updated!
Hornung418
09-18-2011, 12:19 AM
Dean...Bumping this thread. Wondering if there is interest in Carbon Fiber Sedan Roofs. I'm ready to ditch my sunroof in favor of lower CoG and filling the hole in my roof where my stinger currently leaks water into the interior. I'm not concerned about the weave because it's going to be painted eventually. Need new glass at some point so it will be poignant to take advantage of the glass being out. Let me know if you're willing to tackle this project. I'd like to be the first Sedan with a CF roof, unless someone want's to come forward.
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