Paper pulp moulded core to make carbon fiber tube- please help

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#1

Forum,

I am new to Carbon Fiber making…I need to make an irregular and bent carbon fiber tube with super cheap materials.

To be able to pull out the tube easily, I am planning to prepare a core mould rod using plain paper pulp (nothing else), wrap the core mould with Carbon fiber tape into multiple layers. Once it is done, I intend to soak the whole thing in warm water until the pulp inside the tube gets mach-y again and then wash it off.

Sounds simple but I wanted to know how I can avoid the paper from sticking to the resin. I really don’t care if some paper is still left inside inner layer of the tube - but it will be ideal to remove it all.

Could you please advise what materials should I use as coating to the paper-pulp rod before wrapping it with layers of carbon fiber and resin.

Also, please advise if the tape i am going to use can be used to make a tube. I am planning to use the carbon fiber tape similar to one listed here:
http://www.carbonfiber.com.au/prod64.htm

Thanks a lot for your help!

#2

Sounds like you are going the cheap route. Try plastic wrap (saran, etc) as it is either PP or PVC…it should come off easily. Try to get it tight with no wrinkles of course.

#3

If you are using epoxy masking tape will release. If you are using polyester or vinylester, it will eat the tape. Whatever you use please please make sure you do a small test piece first to see if it will work before committing to the full product.

#4

I saw one guy using fish wire, wrapped around a tube, then smeared plasticine over it.

But it was a straight tube, and in a lathe, so the fishwire could be applied easily.

#5

You might want to take a look at the cf sleeves at Soller
http://sollercomposites.com/light-sleeves-sock.html

#6

Can I wrap the paper pulp rod tightly with cling wrap and apply PVA Release agent over it? Can I use any kind of plastic / masking tape that works well with PVA Release agent ?

#7

Main issue is sliding out the mould rod out of carbon fiber tube when tube becomes solid (since the rod is irregular girth and bent). thats why I want to melt the paper pulp at the end. But if I use any tape to cover it, it might be difficult to pull out the tape from inner layer of tube once the paper pulp rod is melted

#8

One way to remove the tape is to first “melt out” the cardboard then attach the start of the tape to a bit of rod in a drill and spin away. The tape will wind onto the rod and off the part. We use this method for removing bag from inside tubes.

#9

I am curious, since I am planing to trial on doing a tube on cf.

what are your dimensions aproximately?

I am planning on doing a cf tube for an intake, I would like to use aquacore but I will be also on the cheap route, at my country there is no aquacore. As I get my cf sleeve, I will do a inner plug with salt’n white eggs, dry on the oven, then cover with cf sleeve and vaccum bag, it should work, and after cure it should be able to disolve with warm wather.

#10

tube’s dimensions range from 1.5 inch to 3 inch diameter and it is irregular. I am going to use the sleeve

Another option I am considering is a sand bag wrapped in tape or plastic - similar to my other approach.This seems to be more re-usable approach. I hope I can peel off the bag and tape easily once I drain the sand. Will experiment with both before I make the real CF tube

#11

I Have used polystyrene covered in vacuum bag material before. Disolve the polystyrene in the tube out with acetone and the bag material pulls out clean. Have done some shaped carbon fiber tillers this way.

#12

I have done prototype air intakes this way also using polystyrene to get the shape. Cover with plastic and tape then overlay. Once cured melt the polystyrene out with acetone (makes a big mess tho!) then pull the plastic out of the middle! job done. If it need to be smoother inside and i can get inside with a brush, you can cover it with flowcoat.