How to make your own Carbon Fiber/Kevlar Bash plate....

[ebrabaek]

Originally Posted by tofire409

FYI...

I just found that Vinegar works well as epoxy on the skin remover.

Also the working time of the MAS epoxy in 34c feels like 40c is kind of short and hot

Needless to say I ended up with a drip on my arm and it cleaned it up nicely.

Now I'll have to wait to see if there are "alterations" needed after the curing.

Ouch........ Most polymers will engage in exothermic runaway when they are mixed over 28 deg.C...... You need to be careful about this specially if you are not using a method of holding the composites in place in the mold during curing. Take a look at it..... If you don`t see any uneven thickness....bubbles formed on the surface ...you most likely got lucky. Not al polymers are even......and some are more tolerant than others..... But generally speaking you should cool the epoxy to 30 deg.C. or below prior to mixing..... Hopefully you got lucky......

Erling

[tofire409]

The finish is fine, it just didn't fully laminate the last layer in a couple of spots. Just checked....

Thankfully!

[ebrabaek]

It is so ironic that the first real bad bash is on the street.......... Hopping of a big curb...... about a foot tall... I did not manual out far enough.....and the front of the plate smacked right in the apex of the curb. I felt the bike jar a bit...and then roll over,...or should I say ...scrape over.... and thought what a %$#@&*%% idiot stunt that was..... Never the less.....after inspection the armor held up just fine..... Just my pride hurt.....




Erling

[BMW_BIKER_KEITH]

nice test earling !!!

[ebrabaek]

Originally Posted by BMW_BIKER_KEITH

nice test earling !!!

Ha-ha..... Yeppers.... I have tried in the dirt plenty of times.... and then I get the Darwin award on the street.....



Erling

[2trally]

I've been fantasizing about fabricating a subframe gas tank out of CF for about a year now. I did some research and came out with the impression I would need to build my own autoclave. As that is way beyond my means at the moment I put that idea off but now... damn I could start tomorrow.

Thank you

Although it would be a good idea to start off with something smaller and less liable to kill me if it fails.

[ebrabaek]

Originally Posted by 2trally

I've been fantasizing about fabricating a subframe gas tank out of CF for about a year now. I did some research and came out with the impression I would need to build my own autoclave. As that is way beyond my means at the moment I put that idea off but now... damn I could start tomorrow.

Thank you

Although it would be a good idea to start off with something smaller and less liable to kill me if it fails.

You don't need an autoclave for that....... Have a look here......

http://www.facebook.com/pages/High-D...37413126297979

[2trally]

Originally Posted by ebrabaek

You don't need an autoclave for that....... Have a look here......

http://www.facebook.com/pages/High-D...37413126297979

Yep, I typed in "carbon fiber production methods" when I was trying to find how to make things from carbon fibre. Of course all the responses google gave me were professional, commercial methods that dealt mostly with pre-preg and autoclaves. I also read about McLaren in the 80's and Eric Buell recently, building their own autoclaves. So I came to the premature conclusion that you had to have an autoclave.

Now that I look back its obvious I was looking in the wrong direction. I should have typed "DIY carbon fiber fabrication" or something similar.

Edit: Just for fun, I googled "DIY carbon fiber fabrication" and immediately came up with this- http://www.eastbaycomposites.com and this- http://www.youtube.com/watch?v=tufaS...ayer_embedded#!

Erling, would you mind checking the eastbay kit? It seems alright. It doesnt look like you could make that much from it but it might be a good place to start.

[ebrabaek]

Originally Posted by 2trally

Yep, I typed in "carbon fiber production methods" when I was trying to find how to make things from carbon fibre. Of course all the responses google gave me were professional, commercial methods that dealt mostly with pre-preg and autoclaves. I also read about McLaren in the 80's and Eric Buell recently, building their own autoclaves. So I came to the premature conclusion that you had to have an autoclave.

Now that I look back its obvious I was looking in the wrong direction. I should have typed "DIY carbon fiber fabrication" or something similar.

Edit: Just for fun, I googled "DIY carbon fiber fabrication" and immediately came up with this- http://www.eastbaycomposites.com and this- http://www.youtube.com/watch?v=tufaS...ayer_embedded#!

Erling, would you mind checking the eastbay kit? It seems alright. It doesnt look like you could make that much from it but it might be a good place to start.

Yeppers...... Autoclaves are a must with prepreg material.... well..... almost all the time, as gases captured in the matrix cannot be rolled....rubbed... or other why by other means be expelled, thus a pressure oven with vacuum hookups.... I tend to steer people clear of the " all in a box" solution, as they rarely does a good job. You are better off looking at the threads I posted. The Facebook page is a great source of knowledge, and you don;t have to be a FB user, with the exception you cannot post up. Where in AZ R U????? I will spend the next 7 days in Phoenix.... Mesa to be exact...... Back on the topic. All you need to know is in the FB page......

[2trally]

I'm in Phoenix actually. You wouldnt happen to be bringing the GS or the DRZ would you? I would love to see them.

[ebrabaek]

Originally Posted by 2trally

I'm in Phoenix actually. You wouldnt happen to be bringing the GS or the DRZ would you? I would love to see them.

I wish I was...... but I am taking the airplane in for an A check at Willie ( Williams Gateway as it used to be called.... Now Mesa Gateway) I will be hanging around there. I'd gladly share other epoxy garage gangsta secrets over a cup of espresso, or other fermented beverages somewhere...... if your time permits. Just pm me......

[ebrabaek]

A long term update......
Had to remove the plate today, to switch to 20-50 oil, and found the left bracket fell off......



Turned out the bond did not hold up, but sometimes you loose. I used HTE and the right side is OK. So it was rebonded... this time with 1618, and it bonds a little better. Another thing making your own composites..... is that you can improve as you go along, and it evolves. I am not sure if you recall, but I covered the inside with K-39 ( ballistic Kevlar), thinking that it would reflect less heat back from the engine. I can tell you that a light yellow surface is not a good choice under the engine..... I know I am not looking in there, but it sure looked like crap. So I scuffed up the whole surface, and it is getting one layer of Carbon fiber..... Gotta look good from both sides.....

[runnin4melife]

Thanks for the lesson learned!

[ebrabaek]

Originally Posted by runnin4melife

Thanks for the lesson learned!

Yeppers..... The HTE works phenomenally in a wet layup. I have yet to see anything stronger. On bonding two cured pieces.... The 1618 or the CLR-HP does a better job... imho. I think it has to do with the hardness. As the HTE becomes rock hard, the void between the two pieces if now filled with the HTE, and the vibrations will destroy it... Like glass... Whereas the 1618 or HP flexes a bit more, withstanding the vibrations. In a wet layup.... That does not apply. So don't get nervous....

[bxr140]

If it matters, we always use structural epoxy to bond two cured pieces. Unless we're horribly negligent with bond line control or voids, failure is always at the part (not the bond) and almost always a delam.