So ive been playing with carbon fiber/kevlar composites for about a month now, wrapping various interior pieces and what not. Ive been using the West System epoxy and harder from Shopmanic.com and have been doing ok with that. Other then various little bubbles popping up everywhere, the resin has worked out fine. Ive got about 4 layers of resin over the entire piece and its still showing a texture in the resin. Ive sanded between each layer of resin, so its less then im sure it would have been without sanding. My question is, how do i go about a smooth finish? Do i use a self leveling clear coat, another epoxy, regular spray can clear coats? Wet sand it smooth and then polish tills it see through again, what? Ive got these pieces sitting around unfinished because i dont know where to go from here. HELP!!!
You’re going to need another good 7-10 layers of epoxy so just keep going. Don’t wait until it fully cures before adding the next layer. As long as it is tacky enough where it won’t sag when you apply the brush then you can start adding the next layer. That way you don’t have to sand it down between layers either. Once you get it to be thick enough, sand everything down flat and get rid of the wavy stuff. I’d start out with 220 grit wet sand. Once it’s all flat, go 400 to 500 and to 800 wet sand. Once all of the cratches are gone go 1500 wet sand. Now you’re ready to apply automotive clear coat, 2-3 layers will do. I’d go the extra step and spray 2 coats of adhesion promoter before the clear coat as well. That’ll keep your clear coat from running and sagging. Now wait for about 2-3 days depending on the weather and then wet sand it again with 1500 or 2000 grit. Then buff, polish and wax.
good luck.
Well thanks for the info on that. I guess there isnt just one specific way for finishing is there? The steps I had been following were from another carbon fiber enthusiast who had decent results with his work. But i had also read of like 5 other formats for finishing. I think with all the labor and money I have had to invest so far in this project, im at the end of my rope. Im going to give this a try and see how that turns out - http://www.eti-usa.com/consum/envtex/envlite.htm
An enthusiast in the UK used it on his carbon fiber work and said it came out crystal clear, smooth, and very deep 3D finish that required no buffing or wet sanding when finished. Its only $20, and its not like i can screw this up any worse. Figure its the final shot though. If this doesnt turn out some what decent, them im sanding all this crap down, glassing it, and painting it the exterior color.
Ah that stuff. Yes that would be the easy way of going at it. I know some people who do that also. The only problem is that this stuff is designed to be used as table top clear coat. Another common name is bar top. It’s the thick shiny coating that you see on tables at restaurants and bars. So what’s the problem you ask? Well, it’s meant for indoor use. Take it outdoor and it’ll turn amber over a short period of time. It might look good for your friend now but check back with him in a little while and see what he has to say.
I don’t mean to discourage you, because there is a solution. Just go one step further of what you plan to do and spray some UV protected clear coat. We use PPG here which is about $190/gallon. You should be able to find a small spray can or something for about $5-$10 at your local automotive parts store.
Evan
Well I gave that clear epoxy finisher that I had linked above and it went on great, was smoothing out nice, and then this morning i noticed that some areas had a whitish hue to them. From the looks of it, from uneven mixing of the chemicals. Once cured, do you think wet sanding will help this? Also, it didnt smooth out as nicely as i was expecting. Still very textured after 2 coats, just not as bad as with the regular West Systems resin. Is there a method to this as well? Im really really at the end of the rope now. Perhaps i need to look in to vaccum bagging?!!
Vacuum bagging isn’t meant to solve that problem and it won’t solve that problem unless you’re doing a female mold. The white hue that you have is from not mixing good enough. Once you pour the resin and hardener together and start mixing, you’ll see the white right the way. You’re supposed to mix it until it all turns clear.
The best way to salvage what you have now is to sand it down smooth with 150. Then 500 wet sand, then spray it with automotive clear. Polish and buff about 48 hours after that once the clear has fully cured.
Sounds good. Appreciate the help. The spray automotive clear… is this available at an auto part store like Pepboys/AutoZone, or is this a professional grade spray that I will need to order from a paint supply store?
The professional stuff isn’t available in a spray can, unless you get them online for about $20. Just get the Krylon or whatever brand they have at Pepboys/Autozone
If i just strip down these interior panels I was wrapping, you sure you can’t wrap them for me? 
let me know, here’s my number at the shop (213) 746-6339
Evan - what is the adehesion promoter that you mention? I have never heard of this, but I’m interested because I’m worried that my clear coat is going to delaminate from my epoxy.
edit: double post
Matt,
It helps the clear coat stick to the surface better. It also helps the clear coat from sagging and running on uneven surfaces. We use it for pretty much everything we do over here. You can find some online by the name of Bulldog Adhesion Promotor for about $10-$12 a can. It’s a bit pricey so you might want to check with your local Autozone or Kragen. I believe Krylon makes their own for about $4-$5 a can.
Good luck,
Evan
Just an update…
Unfortunatly the process didnt work out that well for me. With the time, tools, and work space alotted to me, it wasnt going to get done the right way. Came down to crunch time for a big show I had and in a last minute decision, $200 of carbon fiber and resin was covered with OEM grade automotive vinyl. 
Made me want to cry doing that.
So im thinking i need to take these panels out next month, and send new panels to you to take care of for me, Evan. Up for the challenge? If you want to see pictures of the panels to be wrapped, id be more then happy to post them on here for ya to see. Wanna help me out?!!! Say yes, say yes!
yeah just send me the pictures of what you have done. Hopefully I can help you fix it without having to send it to me. But if it comes down to that then I’ll take care of you.
Evan