Projects on my 05 R1 - Composite Rookie

General Composites Discussions Showcase
#1

First off this site is outstanding - lots of bike projects…:slight_smile:

Been messing around with composites for a year as a hobby, just starting to get through the confusion of v-ester / p-ester / epoxy compatibility which sucks.

Got good at making flat carbon / kevlar plates on glass & doing easy parts.

Stepping it up & working with 2part Urethane Pour Foam 4lb & Kleen Klay making shapes for plugs.

To avoid problems im just going to keep using epoxy products (USComposites) is my store so far.

Currently modifying my air induction system - working on the airbox now.

Used a 2 part Urethane pour foam to get a copy of the space.

As you can see its much larger than stock.

Going to keep one part of the stock box…

There are several ways to go from here but things are progressing.

#2

My motor is getting modded so I cant align the airbox yet - moved to part 2 of the project & started work on an extra ram air scoop.

The rational voices told me not to but the demons told me to grab the grinder & just do it. So I crossed the line & hogged out the pre-filter area in the frame.

Spent many hours clay molding an air scoop for “forced” ram air in the center.
Kinda like what Yamaha says about the new R1 which is different than the regular ram air.

Had 2 major issues making the part as I wanted to catch the air in front of the radiator & the lower fork clamp clearance when at full turn.

Had to make it in 2 sections & tie them together later.

Turn Clearance.

But worked through that & made a near perfect fitting scoop that will greatly boost air flow & allowed me to relocate the ECU out of the flow also.

Still pretty rough & needs some work but thats about done.

#3

Im currently waiting on a $1000 USComposites order & trying to find the best way to design the airbox for a good seal.

Going to use Uni-Air foam sheets for the filter & custom sized velocity stacks.

If I can get done in time for spring I would also like to redo the intake ducts also.

Goal - To make plugs for redoing in carbon / kevlar.

:o

#4

Looking great and thank you for adding these to the forum. :smiley:

To seal the foam, I like to use PER gel coat or primer gel coat. But use something THICK as most lamination resins are too thin / o body to them!

#5

thanks alot of putting up this site - this is the only way im able to learn this fine art.

have read about making your own special coating with epoxy resin & fillers.

got a variety of products from USC - all epoxy resins but some of there THIN line & THICK line.

also a variety of hardeners from SLOW to FAST setting for various situations.

“hope this has good shelf life” ???

Using different combos of the products I hope to make a epoxy filler paste with these fillers (like bondo kinda but epoxy)

FL-AER050 Aerosil-Cabosil
FL-3M050 3M Glass Bubbles
FL-QC050 Q-Cells
FL-PH025 Phenolic Microballoons
SM-ATH4 ATH - Alumina Trihydrate Hydrated aluminum powder

A good homemade epoxy filler / builder would be nice for sealing the foam or whatever really.

Sand that then a coat of Kleer Koat for a nice hard surface to smooth out for the final surface.

Thats where in heading - is this a bad road ?

I do not mind the cost of epoxy & would like to focus on getting good with this side of the road (ester vs epoxy)

:slight_smile: :confused: :frowning:

#6

Here is my bike as of last year - did a bit of mods since then.

Here is my 06 WR450 supermoto that I put together.

I hope to some day be able to make my own fairings & whatever I dream up…:rolleyes:

#7

As long as you’re using urethane foam, stick to polyester sealers and primers. Don’t deal with the hassle of brushing on epoxy with fillers, and getting a crap finish.
Spray on some gray Duratec primer. Sand and fill bumps and low spots, apply more primer as needed. When sanded smooth, spray on Duratec Hi Gloss coating and you’ll have a beautiful surface to make a mold from.

#8

There seem to be many ways to skin a cat.

I do have some Duratec primer & Duratec Hi-gloss but those being ester based - I didnt want “issues” with them & my epoxy products.

So you say that its cool to do my foam plugs with polyester & then I can make epoxy parts off that with no problems ?

What situations would ester NOT work well with epoxy ?

Thanks Alot guys

#9

Generally, epoxy is safe and will bond to anything, including cured ester based resins.
Generally, ester based resin are only safe for urethane foams and don’t bond well to cured epoxy.

You shouldn’t have any problems making an epoxy mold from a polyester surfaced plug.

#10

Didnt know that - thanks for the info - i need it…:o

#11

Decided to take what I learned from the 1st scoop & do it again.

This is where im at now - kleen klay & alm tape.

Got the clay surface pretty smooth & even using ISO Alcohol on a sponge / heat gun.

  • The surface is still going to need worked so what should I put down first to give me a nice sandable surface NOW OR when I pull it off to fine tune ?

Thick epoxy surface coat with sandable fillers ?
Have: Phenolic microballoons / Q-Cells - 3M Glass bubbles.

OR

Duratec Products

OR

PER Gelcoat

THANKS AGAIN

#12

The whole surface is made from clay? That’s very soft and easy to damage. If you spray or brush anything on it, it won’t stick well and won’t be sandable.
The recommended method is to create the shape from urethane foam, and coat that. Clay is used to fill in any tight areas, and is left exposed.

#13

If I may ask… what parts are you making for your R1 Mike?
airbox and intake maybe?

#14

TET

Dont think im blowing off your advice on the PER stuff but im going to have to keep using epoxy for the winter.

Im working in my basement & PER reeks like a mother. Plus my year old Duratec stuff went bad, which sucks.

I got USComposites - Thin / Thick / Kleer Koat epoxy & a variety of hardeners that probably needs used up before they go bad also ?

FASTRR

YEP

There is a power / motor thread on the R1-forum that talked about the benefits of increasing flow / volume that got me thinking of this. My motor guy hogged out his stock airbox & runs a custom filter, said it really helped with power. I was just going to make some changes to the stock box BUT after looking at all the restrictions still, I decided to try to pull off this as my first project…:eek:

Learned alot so far but alot of frustration thats for sure.

Last night brushed some Thick epoxy resin w/ 1-1 laminating & coating hardener mixed with 3 sanding fillers on the part.
(eliminated the end scoop)

Let the surface coat dry overnight to make the surface semi hard so the clay would not distort when I layed up my glass.

Then layed up my fiber this morning.

Hoping the underside will remain fairly smooth & the fillers will make sanding a bit easyer but learning / testing.

Update tomorrow when I pull it off.

#15

Been messing with this & that - got 3 parts done today.

My fav is the dash for my Wideband A/F gage - gear indicator - lights off switch - A/F record switch.

Key goes right too - stressful dremel work.:cool:

Epoxy - 2 layer 6oz / kevlar layer / 2 layer 6oz.

Glassy surface top & Bottom - Looks ALOT better in person… So proud.