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Old 01-03-2013, 09:46 AM   #1
zoomzu OP
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Overlaying carbon/Kevlar cloth on KLR650 shrouds

So my friend starts talking about composites/carbon fiber stuff. So I get on-line and start looking at materials. I come across this blue hybrid carbon/kevlar cloth.



My shrouds need fixing/replacing. At almost $200 a side.....fix them it is. Now that the overnight temp is in the 20's, good time to work on them.



I tape up the out side.

And fiberglass the inside.

On the other side I used a small piece of kevlar my friend gave me. That's the yellow stuff.


Since I'm not worried about weight or how it looks on the inside, I just slap it on. Just want to get structure back.

After some filling and sanding on the outside looks like I'm ready for the overlay.

I do like the flat look though.

That's not going to happen. They are getting some cloth.
So my buddy is going to help with the overlay, since he has been self teaching do's and do nots, and with alot of help from you fine inmates here. This is his road to learning/experimenting. Just a little light reading.
http://www.advrider.com/forums/showthread.php?t=828372
This weekend should be the moment of overlay.
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zoomzu screwed with this post 01-05-2013 at 11:32 PM Reason: title change
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Old 01-03-2013, 11:26 AM   #2
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Sweet!! We'll be slangin' resin in no time.

Edit: I actually just saw the pictures, Mike (no pics show up at work) and they look great! The FG and Kevlar seem to be holding those cracks together quite well. Once you filled the cracks from the outside, those babies look ready for some overlay.

One thing that you could do before you start cutting into that beautiful fabric is to make a pattern out of an old bed sheet or similar large piece of drapable fabric. You'll want to take into account the wrap around the sides, and the hole in the middle. You'll probably want to wrap around all the edges about two inches in order to ensure that the fabric that is showing has good weave and no loose strands. We may also have to make reliefe cuts in the middle hole to get the fabric to lay nicely, but we can wait and see how well it wants to conform to the shape of the fairing.

Nice pics btw. Keep em comming.

I'm off to sewing class now... *THATS RIGHT! I SAID SEWING CLASS!!*
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therivermonster screwed with this post 01-03-2013 at 06:25 PM
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Old 01-05-2013, 11:31 PM   #3
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Overlaying kevlar/carbon cloth on KLR650 Shrouds

Getting ready to put some cloth on.

Slathered up the shroud with some epoxy to stick the cloth to.

Overlayed the cloth on had some problems getting the cloth to stick to the backside. Wanted to wrap over the edges. The cloth wouldn't stick with epoxy so we cut the cloth. I'm hoping to still get a smooth edge after all the epoxy sanding and clear coating. So far it's not too bad. In hind site I would've taped the cloth to the back, and after the first coat cured. I would have epxoied the back side.

Here's after I trimmed them up after the first coat cure.


Here's a close up with a wet third coat. I still have a bunch of sanding to do to get them smooth. But they are starting to look pretty good.
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Old 01-06-2013, 08:33 AM   #4
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After the 3rd coat cured I did a little light sanding, to knock down some high points. immediately after I start sanding, I see blue. I'm sanding the Kevlar. I don't want to sand through the fabric so I keep it light.

I guess more coats to get some build up.

When I trimmed the ends I used a Air dia. grinder with a carbon cut off wheel. and a respirator.
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Old 01-06-2013, 01:24 PM   #5
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Those are looking good, Mike. That Kevlar seems to be a bit of a trouble maker when it comes to cutting. To be honest, I'm not looking forward to cutting it myself.

Keep the pics comming.
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Old 01-06-2013, 10:35 PM   #6
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Quote:
Originally Posted by zoomzu View Post
After the 3rd coat cured I did a little light sanding, to knock down some high points. immediately after I start sanding, I see blue. I'm sanding the Kevlar. I don't want to sand through the fabric so I keep it light.
First, They turned out real nice!


Second, It's a little late now but...

The thing to do when using Kevlar is add one(or more) 6oz layer of FG cloth on top of the Kevlar for a final layer. Lay both(or however many you are using) pieces at the same time. When it dries you will never see the FG, just the Kevlar. Then you have some leeway for sanding/smoothing/polishing, etc.
To do it now, you would have to sand the Kevlar for the new epoxy/FG to adhere. The problem with that, as you probably have already seen is, the Kevlar will start to fray.

You may get by with ever so lightly hand sanding and applying a top layer of FG, if you choose to do so. It may also be very time consuming.

Good luck!
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bwalsh screwed with this post 01-06-2013 at 10:41 PM
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Old 01-06-2013, 10:40 PM   #7
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Those are looking good, Mike. That Kevlar seems to be a bit of a trouble maker when it comes to cutting. To be honest, I'm not looking forward to cutting it myself.

Keep the pics comming.
Good scissors are the key! I have a pair of dressmakers scissors for cutting Kevlar. Similar to these...


They work but there are scissors specifically made for cutting Kevlar...


As always, never use them for cutting ANYTHING else.
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Old 01-07-2013, 09:54 AM   #8
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nice job on the shrouds!
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Old 01-07-2013, 04:21 PM   #9
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Quote:
Originally Posted by bwalsh View Post
First, They turned out real nice!


Second, It's a little late now but...

The thing to do when using Kevlar is add one(or more) 6oz layer of FG cloth on top of the Kevlar for a final layer. Lay both(or however many you are using) pieces at the same time. When it dries you will never see the FG, just the Kevlar. Then you have some leeway for sanding/smoothing/polishing, etc.
To do it now, you would have to sand the Kevlar for the new epoxy/FG to adhere. The problem with that, as you probably have already seen is, the Kevlar will start to fray.

You may get by with ever so lightly hand sanding and applying a top layer of FG, if you choose to do so. It may also be very time consuming.

Good luck!
Thanks for the info, if there is a next time I'll try that. I don't think I will this time around.
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Old 01-07-2013, 04:26 PM   #10
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Quote:
Originally Posted by bwalsh View Post
Good scissors are the key! I have a pair of dressmakers scissors for cutting Kevlar. Similar to these...


They work but there are scissors specifically made for cutting Kevlar...


As always, never use them for cutting ANYTHING else.
I have some Clauss kevlar scissors. They work great.

Quote:
Originally Posted by kubiak View Post
nice job on the shrouds!

thanks, I have a bit more that I want to do. Make them all shiny.
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Old 01-07-2013, 06:43 PM   #11
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Thanks for the info, if there is a next time I'll try that. I don't think I will this time around.
I don't blame you. I wouldn't either. What you have will last a long time.


Quote:
Originally Posted by zoomzu View Post
I have some Clauss kevlar scissors. They work great.
The second pic was one I grabbed on line and were NOT Kevlar scissors.
The Clauss scissors look like the hot ticket!
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Old 01-09-2013, 04:38 PM   #12
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Ok, just about layered up, and I'll start sanding to get it smooth.


the thing I like about this cloth is one direction it reflects blue. In the other the carbon.


This is my trouble area. I may just leave this semi bumpy.


I think it will still look ok. Besides from 10' nobody will know anyway. It is a KLR, not one of those over priced bikes you're scared to get dirty.
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Old 01-10-2013, 09:14 AM   #13
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I think it will still look ok. Besides from 10' nobody will know anyway. It is a KLR, not one of those over priced bikes you're scared to get dirty.
They look great! Do you have a link for where you bought the material?
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Old 01-10-2013, 09:43 AM   #14
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They look great! Do you have a link for where you bought the material?
I bought the cloth on ebay, but you can also get it here.

http://www.uscomposites.com/
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Old 01-10-2013, 09:46 AM   #15
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I'm about 90% done sanding on one side.

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