How to make your own Carbon Fiber fairing.... - Page 3

jaycommando · 09-03-2010, 07:05 PM

If you don't like it and it looks good I'll Buy it for Cost plus your estimation of labour...
Nothing like good craftsmanship witnessed and recommended!
you have a talent

MSH · 09-03-2010, 08:33 PM

Quote:

Originally Posted by jaycommando

If you don't like it and it looks good I'll Buy it for Cost plus your estimation of labour...
Nothing like good craftsmanship witnessed and recommended!
you have a talent

I had him at hello. Buzz off.

ebrabaek · 09-03-2010, 08:53 PM

Quote:

Originally Posted by jaycommando

If you don't like it and it looks good I'll Buy it for Cost plus your estimation of labour...
Nothing like good craftsmanship witnessed and recommended!
you have a talent

....... So far I like it........

Erling

ebrabaek · 09-03-2010, 08:53 PM

Quote:

Originally Posted by MSH

I had him at hello. Buzz off.

....

Erling

ebrabaek · 09-04-2010, 09:03 PM

Sorry...... But I won`t be working on the project until after the 9`th of sept.
I`m going to socal beginning tomorrow. I`l pick it up again when I get home....

Erling

HighTechCoonass · 09-05-2010, 07:17 AM

Cant wait!!!!! Excellent work!!!

GSranger · 09-05-2010, 11:33 AM

Quote:

Originally Posted by ebrabaek

Sorry...... But I won`t be working on the project until after the 9`th of sept.
I`m going to socal beginning tomorrow. I`l pick it up again when I get home....

Erling

ebrabaek · 09-12-2010, 01:38 PM

Back from socal yesterday......On with it we go......There are really two ways you can do this. You need to build the mold.......But the difference is.....One method..... You take the mold on and off fitting each piece.......and so forth.....You can then lay the mold on the table, and layup the composites...... That method is nice....because you can work at a workstation....sipping whatever you want. Main two drawbacks with that method is Mold is wobbly, and might shift during layup.....and as you design as you go along....one can loose track of how you want it to look.
The other way is simply to cover the bike sort of like when you paint a room.... Then you glue up each piece at a time......Mold stays on the bike during construction. Pluses are rigid mold, since you are using the bike as support.....Second.... It is easy to change design as you go along......Bad....could make a mess with drips on the bike, and the cloth could sag when you wet it in. I used the first method when I build the CF skid plate.... And the second method with the fairing. It just depends on what you would like..... Hmm....Tue. thur.`s....method one.....wed.....fri...`s....number 2......

.
The you get the Styrofoam....Pick a point and begin.......

Note the foam being added to the left side...... Right ( picture) side still need to have foam added......

Then you cut corners......edges....sand to your liking......

There will always be voids in the foam...... You can fill it with what ever you can find...... Clay.....booger....Pilfer your kiddoes playdough..... Or I just happened to have some " clay epoxy" left....... Just fill in the gaps...

Then onto a few layers of release agent.......

Then use an old sheet of fabric.... to get the rough cut that you can use as a template cutting the carbon fiber.....

Then I only had enough CF for two layers........Waiting on ups on Tuesday.....

I mixed 228 grams of resin......(total weight).....And with the importance of getting the fabric right....... I would not recommend more than two layers at a time.....Well....at least in the hot desert.... as the setting time is reduced.
A few things to mention for your consideration...... The fairing you build......is your own idea. The design is your own, and therefore taste is often very different from person to person. Byt your high ehhhh...middle school sculpting days will be tested here...... If you can build a mold.....then the layup is really the easy part. Since I am sort of designing as I go along.....plastic screen in mind...... It is hard to imagine the final product until the end...... And one of the neat things with the composites......is you can always remove material......but it`s harder to add it. Keeping that in mind...... I made the fairing a little big...... And plan on cutting it to shape when I finish two more layers, and have time to play with the shields. It is a little wider than I would have liked......But I have no choice....since I have the dashboard widened with the gps layout.
Until Tuesday.....

Erling

MSH · 09-12-2010, 09:01 PM

Till Tuesday nothing! I want more now! :-). Looks awesome. Did you make me one?

ebrabaek · 09-13-2010, 07:06 AM

Quote:

Originally Posted by MSH

Till Tuesday nothing! I want more now! :-). Looks awesome. Did you make me one?

I know...I know.....

.... Have`nt even made myself one yet......

..... Tell you what..... We can meet in Moab.......I`l help you make one......Nothing like parking lot compositing......

....

Erling

MSH · 09-13-2010, 08:18 AM

Quote:

Originally Posted by ebrabaek

Nothing like parking lot compositing......

....

Thats what she said.

ebrabaek · 09-13-2010, 09:41 AM

Quote:

Originally Posted by MSH

Thats what she said.

....

Erling

ebrabaek · 09-14-2010, 09:50 AM

So in anticipation of the ups truck arriving with the CF today...... I took off the fairing...... And cleaned up the bike.

Put the fairing ( now two layers of cf+ foam pieces).....and made a nice work stand....... Cleaned the edges a little, so the next 3 layers will conform nicely......

It is almost impossible to NOT bend the edges....corners of the wet cf cloth when they rest on the bike ( or any piece) It is better to have the wet cf cloth hang over about 1 inch all around, so not to9 have any sharp bends.
I am hoping to add the 3 layers tonight, so I can begin the most fun part tomorrow...... The shaping. But... Tonight is movie night, and I just finished calibrating our new processor....... So Prince of Persia will sound awesome........ Until then ......

Erling

ebrabaek · 09-15-2010, 10:07 AM

Today was sanding day......

... Even though you use release agent on the foam...... It still sticks. That is mostly in part to the contours. If you did not use it.... The resin would penetrate by far deeper.
Fairing was cut to it`s rough dimensions....... Then sanded front and back. You don`t have to sand the front.... But from a design point, I find it better to design....ie. cut...reform.... the CF pieces when they don`t stare you straight in your face with the extreme glossy surface. The inside had to go..... Looked like.....styropoxyfiber.....

. Here it is before the trimming.....
I know ...I know.... Way big.......

The fit came out awesome.... The bottom brackets line up great.... And I just need to make 1/4 inch spacers ( Like I did on the skid plate mounts) on the other 4 holes..... That represent the void created by the foam removal...

All in all.... even though it`s a bit bigger than I`d hoped.....( no way around it due to my redesigned cockpit layout with the gps) I am now leaning towards using the stock shield. I personally really like that design, and with the fairing giving it a head start in height.... I think they will comment each other nicely.......

Erling

MSH · 09-15-2010, 12:04 PM

Let me know when mine is ready!

09-03-2010, 07:05 PM	#31
jaycommando Gnarly Adventurer Joined: Jun 2009 Location: Cirencester, Glos, UK Oddometer: 103	Shameless... If you don't like it and it looks good I'll Buy it for Cost plus your estimation of labour... Nothing like good craftsmanship witnessed and recommended! you have a talent __________________ Jay. Just because I stink of petrol, look like shit and still smile doesn't mean I've not been having fun! Soldiers Do It With Their Helmets ON!!

09-05-2010, 07:17 AM	#36
HighTechCoonass Living the Dream.... Joined: Jan 2005 Location: land of the swamps!, Cajun Country LA Oddometer: 2,097	Cant wait!!!!! Excellent work!!! __________________ The F800gs Snatchy Throttle Fix Boost your Beamer...BMW efi GS Power Controller - l Now the Juice NEW!TheJUICE

09-12-2010, 01:38 PM	#38
ebrabaek ^OP Beastly Adventurer Joined: Jan 2010 Location: El Paso,NM Oddometer: 2,871	Back from socal yesterday......On with it we go......There are really two ways you can do this. You need to build the mold.......But the difference is.....One method..... You take the mold on and off fitting each piece.......and so forth.....You can then lay the mold on the table, and layup the composites...... That method is nice....because you can work at a workstation....sipping whatever you want. Main two drawbacks with that method is Mold is wobbly, and might shift during layup.....and as you design as you go along....one can loose track of how you want it to look. The other way is simply to cover the bike sort of like when you paint a room.... Then you glue up each piece at a time......Mold stays on the bike during construction. Pluses are rigid mold, since you are using the bike as support.....Second.... It is easy to change design as you go along......Bad....could make a mess with drips on the bike, and the cloth could sag when you wet it in. I used the first method when I build the CF skid plate.... And the second method with the fairing. It just depends on what you would like..... Hmm....Tue. thur.`s....method one.....wed.....fri...`s....number 2....... The you get the Styrofoam....Pick a point and begin....... Note the foam being added to the left side...... Right ( picture) side still need to have foam added...... Then you cut corners......edges....sand to your liking...... There will always be voids in the foam...... You can fill it with what ever you can find...... Clay.....booger....Pilfer your kiddoes playdough..... Or I just happened to have some " clay epoxy" left....... Just fill in the gaps... Then onto a few layers of release agent....... Then use an old sheet of fabric.... to get the rough cut that you can use as a template cutting the carbon fiber..... Then I only had enough CF for two layers........Waiting on ups on Tuesday..... I mixed 228 grams of resin......(total weight).....And with the importance of getting the fabric right....... I would not recommend more than two layers at a time.....Well....at least in the hot desert.... as the setting time is reduced. A few things to mention for your consideration...... The fairing you build......is your own idea. The design is your own, and therefore taste is often very different from person to person. Byt your high ehhhh...middle school sculpting days will be tested here...... If you can build a mold.....then the layup is really the easy part. Since I am sort of designing as I go along.....plastic screen in mind...... It is hard to imagine the final product until the end...... And one of the neat things with the composites......is you can always remove material......but it`s harder to add it. Keeping that in mind...... I made the fairing a little big...... And plan on cutting it to shape when I finish two more layers, and have time to play with the shields. It is a little wider than I would have liked......But I have no choice....since I have the dashboard widened with the gps layout. Until Tuesday..... Erling

09-12-2010, 09:01 PM	#39
MSH The Salt Joined: Mar 2007 Location: Utah Oddometer: 3,026	Till Tuesday nothing! I want more now! :-). Looks awesome. Did you make me one? __________________ *~ BMWF800GS* ~ "Not all those who wander are lost"

09-15-2010, 10:07 AM	#44
ebrabaek ^OP Beastly Adventurer Joined: Jan 2010 Location: El Paso,NM Oddometer: 2,871	Today was sanding day......... Even though you use release agent on the foam...... It still sticks. That is mostly in part to the contours. If you did not use it.... The resin would penetrate by far deeper. Fairing was cut to it`s rough dimensions....... Then sanded front and back. You don`t have to sand the front.... But from a design point, I find it better to design....ie. cut...reform.... the CF pieces when they don`t stare you straight in your face with the extreme glossy surface. The inside had to go..... Looked like.....styropoxyfiber...... Here it is before the trimming..... I know ...I know.... Way big....... The fit came out awesome.... The bottom brackets line up great.... And I just need to make 1/4 inch spacers ( Like I did on the skid plate mounts) on the other 4 holes..... That represent the void created by the foam removal... All in all.... even though it`s a bit bigger than I`d hoped.....( no way around it due to my redesigned cockpit layout with the gps) I am now leaning towards using the stock shield. I personally really like that design, and with the fairing giving it a head start in height.... I think they will comment each other nicely....... Erling

09-04-2010, 09:03 PM	#35
ebrabaek ^OP Beastly Adventurer Joined: Jan 2010 Location: El Paso,NM Oddometer: 2,871	Sorry...... But I won`t be working on the project until after the 9`th of sept. I`m going to socal beginning tomorrow. I`l pick it up again when I get home.... Erling

09-14-2010, 09:50 AM	#43
ebrabaek ^OP Beastly Adventurer Joined: Jan 2010 Location: El Paso,NM Oddometer: 2,871	So in anticipation of the ups truck arriving with the CF today...... I took off the fairing...... And cleaned up the bike. Put the fairing ( now two layers of cf+ foam pieces).....and made a nice work stand....... Cleaned the edges a little, so the next 3 layers will conform nicely...... It is almost impossible to NOT bend the edges....corners of the wet cf cloth when they rest on the bike ( or any piece) It is better to have the wet cf cloth hang over about 1 inch all around, so not to9 have any sharp bends. I am hoping to add the 3 layers tonight, so I can begin the most fun part tomorrow...... The shaping. But... Tonight is movie night, and I just finished calibrating our new processor....... So Prince of Persia will sound awesome........ Until then ...... Erling

09-15-2010, 12:04 PM	#45
MSH The Salt Joined: Mar 2007 Location: Utah Oddometer: 3,026	Let me know when mine is ready! __________________ *~ BMWF800GS* ~ "Not all those who wander are lost"

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