Carbon Fiber wheel copy?

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#1

Hey guys,

A friend of mine asked if I can build him a Carbon wheels set for a show car, as in the wheels do not have to function, just look good on a showroom floor, but at least hold the car’s weight.

He wants me to copy the shape of a certain pressed steel wheel, I told him I could wrap it, but he wants a solid carbon wheel :confused:

Anyway, I have no idea how to even start, I was thinking I could make a multi-piece mold with 4 parts for the rim, molded from the outside, and then a separate mold for the face of the rim.

The rim has to have a shape similar to this, but doesn’t have to be a perfect copy.

Do you think this is possible? Any tips or ideas are welcome.

Regards
Jacques

#2

It can be made however it will need to be an engineered selection of materials to be at all safe and useable. The loads from tire pressure alone will be great not to mention a vehicles weight and exposure to road conditions etc.

Mold-wise I see no issues aside from where there may be some draft change requirements near the hubcap mount bulges. You’ll need to adjust those points or make silicone caul-plates there to make removal easier.

You’ll want to carefully consider the use of Kevlar located at friction points such as the lug nut holes and rim edges for mounting/dismounting of tires. I personally would add titanium or stainless washers or some type of T-nuts embedded as the top friction point for lugs.

1)-Face of wheel mold.
2)- Two part barrel mold.
3)-Possibly a inner barrel mold as well for added appearance and strength.

That would be three final pieces secondarily bonded and post cured.

NOTE: I don’t recommend a wet lay-up at any consideration! Pre-preg work and autoclave cure or at the least Infusion with post cure with a very comparable resin/cloth system. Carefully followed by manufacture post cure schedule.

Keep us posted.

#3

I’d do it for 20 grand!!! Otherwise like world said. Your gonna want to make a 3 piece wheel.

#4

I think you can do this with a two part split mould for the rim only and then another mould for the centre piece.

Make the rim as a single piece from the split moulds.
Make the centre as a separate part and bond this in after with extra laminate for strength.

You may need to make some kind of bonding jig to ensure the centre is set in the correct position.

#5

Will he give in and let you use BBS or other brand lip and barrel and then make a carbon/kevlar wheel face that bolts in?

Like this?

#6

Hi guys!

First time posting here. Very cool forum.

Jacques, do you like those rims? Why duplicate them in carbon? I mean, wouldn’t it be nice to make a new design??

Regards from Spain!

#7

If it’s just for show there’s absolutely not reason to go any other route than wrapping. Just convince him it’ll do. The easiest way to do this will be by showing him a budget :stuck_out_tongue:

#8

I am not a fan of fake carbon products but this looks ideal for your project the wheel is going to be a pain to wrap in and a bigger pain to copy.
[ame=“http://www.youtube.com/watch?v=9ZES1hwcuC0”]Hydro Dipping Alloy Wheel - wicked graphix peterlee - YouTube[/ame]
Regards Chris
www.carbonfibreworks.co.uk