Hello from Ontario Canada

First Stop Introductions
#1

I am located in the city of Hamilton…and have 0 experience with fiber.

I’m a newb thats going to be building a carbon fiber full suspension free ride bike.

I am planning on using a uni fiber to build, with a foam core, wet layup and vacuum bagging the frame.

Haven’t picked a uni fiber yet, the choices are overwhelming, and not having working with fiber, I’m not sure what will wrap nice on tight curves, bends and joints.
Any suggestions?

Was debating whether a thin layer of kevlar might useful prior to the final layer.

I’ve built/welded up a bike in steel so I am familiar with the bike building process, fiber is new to me.

maybe will put some twill on the last layer for the the bling factor.

Cheers from Canada!

#2

Gutsy dude, you can get seriously hurt taking big drops and having your frame break.

Don’t let that dissuade you but plan on building 2-3 bikes so you can destructively test the frames either statically with sandbags, hydraulics, etc. or dynamically using drop tests.

#3

^^ He raises a good point, happy to see a local on the board though, I am in Oakville and have built a CF frame before as a proto-type which is used for the design purpose and then sent over to Taiwan for mass production. We also repair them on the regular for several bike shops as filler work.

Most tools now, even the proto-types are built in aluminum 2024-T6. Rarely are composite moulds used, at least thats our experience.

If it is to test, I would recommend designing the couplers (joints) and buying CF tube to create your first proto-type to minimize some potential frustrations you may experience. As you noted being new to composites and mounting a task such as a building a total frame is like going from the pot into the fire…there is much involved.

Hope it doesn’t discourage you, I wish the best with it, but I would spend sometime learning the principals of vacuum infusion and RTM (RTM is the process on how the tubes are created, infusion methods) and also constructed with a bladder or center die to form from.

Welcome to the board :slight_smile:

#4

I am aware of the risks of mountain biking and the risks of being a test pilot. Its going to be a one off bike, whether that takes 3 or 4 frames to get there via testing…doesn’t matter. I’m not really into the really big drops…so it will tend to be used more like a all mountain rig…with the freeride/DH geometry.

There are lots of aspects to a full suspension bike irregardless of frame material.

I fully expect lots of difficulty, problems and failure.

I am motivated and committed to the project so its going to happen and I am to stubborn to be dissauded or discouraged :slight_smile:

Thanks for the feedback!

cool to see someone from the GTA :slight_smile:

#5

One of the nice things about composites is that for your prototype you can non-destructively test and then keep adding layers where needed. Not as efficient as co-curing your layup but it works.

But to do so without breaking things you’ll have to know your local stress. The best way to do this is to run a finite element analysis to get the stress distribution and then stain gauge the critical hot spots and several validation locations (where the stress doesn’t change much so that you know your data is good as compared to the FEA). Then do load testing at below your peak (limit) load and add or remove material as needed. Gradually bring the load testing up to limit.

If you can’t do the FEA or strain gauging then get to be friends <buy beer> with a local college engineering student and if they’re motivated <lots of beer> then you will have a fun little project.

#6

So much truth in this statement

#7

SLS where do you buy you composites from?

I only know of aircraftspruce and composite canada in the GTA.

Are there other stores or distributors in canada that carry a larger selection?

Or do you order online?

#8

PM’ing you now

#9

Pm’s won’t work for Hammerhead