How should I produce these parts?

General Composites Discussions Composites Talk
#1

Hi,
I’d like to get some ideas regarding the best way to produce these parts from carbon fiber. I have been doing overlay and vacuum infusion work producing other parts, but when it comes to making these paddles I’m afraid maybe it’s a bit much for the DIY. They need to be cosmetically accurate in the front with the cloth weave visible and the rear can be painted or if possible the weave showing.
They are F1 shift paddles from a Ferrari 599 that I would like to reproduce in carbon and sale.

How do you think I should make them? I need ideas please…

#2

Extreme,

Awesome project! I make carbon fiber paddles for the Lamborghini Murcielago, LP640, and the SV670. I can’t show the molds (customer owned and contract) and although we are existing together in a similar market (potential conflict of interest) we are all family here on the forum… so here we go!

There are a couple of ways to make the mold (from what I’ve experienced). One way is to capture all of the edging detail in the mold resulting in less stress trimming the final piece, but resulting in a lot more technical layup.

The other way is to make the mold contour to the swoop of the paddle but somewhat flat (not really capturing the edging so much, and defining the trim by a scribe line in the mold face). Resulting in a very easy layup, but more attention needed when trimming.

With regards to the mounting hole recesses, it’s your preference… you can make the mold flat and countersink drill it post cure, or you can grab that detail in the mold and address the opposite side of the paddle post cure.

I found a way to make a multi-piece tool that captures both the front side and rear side of the paddle so that the composites are “smashed/sandwiched” in between the front and back side molds, then infused (sort or RTM Closed or RTM-Light).

Let me know if there is anything I can help you with, PM me if you’d like. Paddles are fun to make, they can be as easy or as complex as you want… which is sort of the fun of composites in the first place!

-Corban

#3

Corban, thanks for the ideas I won’t be taking on the project for a bit. I will hit you up with some question when the time comes.

Don’t worry I’m a Ferrari fan so no Lambo parts for me. :slight_smile:

#4

Extreme,

Haha, the famous Ferrari vs Lamborghini rivalry lives on! I’ve been around exotics for as long as I remember, I was always raised with a bias towards Lamborghini, but in the end, I have great respects for Ferrari… they do make a fine machine!

No worries man, I’m here to help, seriously… just let me know when you’re ready and we’ll get into the details so you can produce a very market worth item, both for the customer and for your profits!

-Corban

#5

Looking at these parts I wonder if a wet layup or even prepreg, with expancel as a core (expands when heated) would be succesful.

#6

Solid parts would be possible. Mould the 2 halves, fill them up and clamp together would be quite easy. Or layup a solid piece of carbon, and shape afterwards, even easier, but leaves the edges just plain carbon black…

#7

Thanks for the ideas everyone.
I hope to get started on them soon and I will post pics of the method and results as I learn.

#8

I saw a friend making flat sheets with wet layup with good results.

He used a glass table and wet out the carbon on it, then he used a flexible clear plastic piece(plexi glass or lexan from the looks of it) and “rolled” it onto the wet fabric. eg. he put the edge of the plastic on the fabric then by lightly flexing it, laying it down from left to right, till it is flat on the carbon.

He had no pinholes from what I could see, but I’m sure it would take some practice to get it perfect.

#9

ive always been curious how these would be made… so you guys would make these solid CF? how many layers at What ounce would you use to make this?

#10

I would think that if you want to simply replicate, it depends upon the type and weight of the fabric and how thick the original part was.

Then when you have knowledge of how thick that weight of material is at a given percentage of fibre/resin content you would add the amount of layers required so that it was the same thickness as the original!