Making a plug? Pictures inside.

General Composites Discussions Composites Talk
#1

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I am going to make a fender for this rear swingarm, but I just wanted to ask what would be the best route? I used tape and cardboard to cover the wheel and swingarm. I also sprayed it down with PVA, so the fibreglass wouldn’t get stuck. Should I just layup a couple of layers of bi-directional cloth, then layup up some chopped strand mat over that. Then just continue until it’s thick enough? I was then planning to smooth over with bondo, sand, and skim coat of Q-cells, sand again then spray grey primer, sand, and sand then buff. Then use that as a plug and make a mold off of that then finally make Carbon fibre part. Is this the right way or is there a better way? This is what i’m working on.

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#2

wouldn’t it be easier to get something with a wide curve shape you’re after, then make a fiberglass copy of that, then use cardboard/clay/whatever to mold it to the fender, then smooth everything out w/ body filer and them you have a plug.

edit: nvm, the pic’s working now and looks like your method would work better.

#3

I figured since I have the original parts, why not just you that, then make something that would need to be modified to fit it. I thought it would be start with the same size then build up the plug, smooth out, then make mold.

#4

Yeah you’re pretty much on the right track there Rick.

#5

Evan thank you for the kind words. I have a quick question, what would be the best way to build up the thickness in the plug?

#6

Most sufficient way would be sheet wax. But working with what you have is fine too. Wet out a piece of fiberglass mat and drape it over your part there and repeat until you think you’ve reached the desired thickness. Work the fiberglass in with a brush and get everything as smooth as you can. After that it’s all a matter of bondo and sanding.

#7

… or pour some of that foam you have, let it expand and then carve & shape it down into what you want. Smooth it out afterward with bondo and primer. This is probably a lot quicker than going the fiberglass route.

#8

Just a progress report on my plug. This is after the second layer of chopped strand mat. I’ll let it cure over night and check the thickness tomorrow morning. I want the finished hugger to be as close to the tire as possible. [/img][/b]

#9

that’s looking good so far

#10

It sure is a lot easier (like cutting cheese) to cut the layup while in the “B” stage with a metal box cutter…

#11


Will a vacuum cleaner create enough suction to have any effect on a wet layup.

#12

what are you going to do with the vacuum cleaner?

#13

:smiley:

#14


Clean the plug? :lol: I friend sent me a post from a Motorcycle forum of some guy in Europe who makes small CF parts with a regular home vacuum cleaner.

#15

Vacuum cleaners don’t work because it’s designed to move air. Once all of the air is removed from your laminate and there is nothing left to move, the motor will overheat and die.

#16

Every time I see that paid commercial on the bags you use to compress and store clothing I wonder if it would work.

Then again I already have a real setup so why bother. If you intend on getting into this business do it the right way.

#17


Here are some more pictures on my progress on my plug. It’s coming slowly, I wish I had more time to work on it.

#18

[/img]Here is another angle of it.

#19

Just my .02…I would have left the mounting flange to go out to the edge of the swing arm. Even after it is done, you can go back and cut it down more if you want to, but good luck if you want to add it back again.

Also, when the resin is in a “B” stage (not wet, not hard cured) it is real easy to cut it with a metal (don’t try a cheap plastic as they are PS) box knife with a hooked blade to cut it like cheese.

I should don’t want to be on that bike at speed when some thick debris gets between the fender and the tire…instance lock up?

#20

why aren’t you using the original as the plug?