Looking for some advice on what technique to use, Carbon Front Grill.

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#1

Hi there well i thought this would be the best place to ask for some advice, as there are some very impressive composite fabrications going on, and some knowledgeable people around by the looks of things :smiley:

So where to start, i have been working with FRP for a couple of years now on and off, and have made a few moulds and parts, nothing spectacular and have all been made using wet layup with CSM, using epoxy gelcoat, and resin.

Now ive had a little play with some 2x2 twill weave carbon, only a sample i purchased so not much, but it deffinatly is tricker to layup than CSM! Haha

Therefore I am looking for some advice on producing a Carbon fibre front grill, it has some pretty complex curves to it and just want to know how you guys would go about it, it is mainly for aesthetics than to reduce weight. So therefore would rather wet layup if you think its possible, although I would look into Vacuum infusion etc if its required, although I have no experience with it.

So heres a picture of the Grill design these are made FRP, after taking a mould of the original. I am planning on making a fresh mould for the new project as the old one has seen better days.

Fitted

Sorry for the essay, and any help will be greatly appriciated :slight_smile:

TO82

#2

Wet layup would be tricky and i would not evan know where to start as i infuse only,

One question i put to you is what resin are you using to laminate csm matt as i tried some epoxy other night and it did not wet out like my regular vynal ester

#3

I agree with Brainstorm that wetlay would be tricky, but I’m sure that’s because we mostly due infusions and handling wet fabric is way different then dry. I think infusion would allow you to get the straightest weave.

Brainstorm - If you are using Chopped Strand Matt, epoxy wont dissolve the binder like VE and poly. They make Continuous Stand Matt for this reason, it has no binder and works with epoxy. Yes they are both “CSM” but you gotta look for the continuous version.

#4

Using csm is not a problem,with epoxy,use a low viscosity resin,and powder bound Csm.

#5

I think you will get the best result by infusion or prepreg. Prepreg is to expensive so I prefer infusion.
You have to cut your material if you dont want too much distortion.
To cut the carbon you can fix it with spray adhesive before cutting it. Than place the fabric with the adhesive to the inner side in the mould.
How to infuse you can take a look at the vid in the MTI Thread.

#6

Thankyou for your replys, first off if infusing the resin, i would still need to sit the carbon in the mould, therefore if i was to coat the mould with resin and then when it reached B stage, sat the cloth into the mould and then wet it out, how would this be different to infusing?

What I mean is I would be taking the same steps by placing the cloth into the mould?

Also how many pieces of carbon cloth would you think it would take to cover the mould for one layer and how would I go about ensuring the meeting of one piece of cloth to the next is hardly visable once cured?

Thanks again, an i will post some pictures of the mould one ive made it mite help to give you an idea of how to place the cloth, I will make some flat edges to the mould incase I do need to use a vacuum.

#7

No no no no if uou infuse you add the cloth dry, no nood for any messy resin. You have unlimited time to get theweave perfect make sure theres no bridging of the bag. Any one who infuses has no excuse not to be making perfect parts as there is no clock ticking against gel time.

Really check out mti video and you will see the full process

#8

Ive seen the video before, but they used spray adhesive to hold the cloth to the mould, therefore I assumed that once you touched it to the mould thats where it was staying, in that aspect it would be the same as placing the cloth onto B stage resin?

How many pieces would you think would be needed to do 1 layer, is it possible to used one peice do you think?

Thanks

#9

No you dont have to use any adhesive people use adhesive to keep the weave straight or to hold into tight places i use it now and then but is not a must so its a step can be skiped.

Its going to be hard to layup with the side been so tight i think i can be done although how neat it is i cannot comment