Help conforming to complex shapes?

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#1

I’ve had a 3 yard roll of carbon for about 2-3 years now and I finally bought some 2 part epoxy from hobby lobby (36oz for $20 with a couponx[http://thefabforums]) and decided it was time to make something.
I started simple with making carbon plates with emblems under the epoxy and got xxxxy and tried to skin my welding helmet.x

Didn’t come out horrible but I certainly rushed it. I used spray tack and laid a layer of carbon followed by more spray tack and another layer because I couldn’t get the carbon to lay nicely.x[http://thefabforums]xI know I suck. All and all its not horrible however when I got to the last corner I had a lot of extra material that folded and wouldn’t lay flat. Is there a trick to shapes like these?

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#2

Hi Defi
Some images would help so members can see what went wrong .
Chris

#3

Unfortunately I didn’t take a photo but if you look closely at the top corner which would be above where your left eye would be you’ll see distortion under the vinyl. At that point is where I had a “fold” of left over material that I couldn’t lay flat and had to cut off.

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#4

Is there any trick to forming carbon around shapes like this without having excess material folding at the end?

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#5

You can try using a different weave of carbon, for example a 5 harness weave will conform to shapes better but you will have a harder time keeping it together. Your other option is to put cuts in the cloth as you go so you don’t end up with the extra material.