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Old 01-19-2011, 09:46 PM   #76
EnderTheX
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Show us your protective gear during sanding

I bet it will be entertaining I know when I was sanding carbon (in my very limited experience) I wore dirty long sleeves and pants in 100 deg Texas heat and a huge respirator. There is nothing worse than carbon fiber dust in your lungs!!!
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Old 01-19-2011, 09:52 PM   #77
ebrabaek OP
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Show us your protective gear during sanding

I bet it will be entertaining I know when I was sanding carbon (in my very limited experience) I wore dirty long sleeves and pants in 100 deg Texas heat and a huge respirator. There is nothing worse than carbon fiber dust in your lungs!!!
I wear this....


That keeps it out of my lungs....... I then put a giant fan behind me....that blows all the dust away from my body....... Rakes up the Carbon Credits really fast....... Works very well..... Your right.... It is almost impossible to protect yourself with a full suit....that material will just work the carbon in to your skin...... Key is to evacuate the dust before it get`s to you.... Thus the prop behind me.....

Erling
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Old 01-19-2011, 10:01 PM   #78
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ebrabaek, is wet sanding possible/practical?
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Old 01-19-2011, 10:06 PM   #79
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ebrabaek, is wet sanding possible/practical?
and how are going to get a good cosmetic finish on the outside?
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I used to say "one day" a lot. But then I got scared I would wait one day too long. So I am doing it all now
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Old 01-20-2011, 06:28 AM   #80
ebrabaek OP
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ebrabaek, is wet sanding possible/practical?
Yes....but not between layers..... Simply because you need coarse grit between layers....... and most wet sanding paper start around 200. And the fact that on the high temp epoxy..... it is so stiff that unless you use a electrical sander........ you will sand sand for days without getting anyway. After final layer of composites.....then you wet sand to your harts dislike.....

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Old 01-20-2011, 06:29 AM   #81
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and how are going to get a good cosmetic finish on the outside?
I know several of you are waiting for this....... You will see.....



Erling
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Old 01-20-2011, 06:33 AM   #82
craftycoder
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I've been curious what the lid will look like and how it will be secured to itself and from prying hands. The only reason I use hard bags is security. Otherwise, they are sort of annoying. Carbon ones may not be though as they are light and don't need to be reshaped after every ride..
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Old 01-20-2011, 06:48 AM   #83
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I've been curious what the lid will look like and how it will be secured to itself and from prying hands. The only reason I use hard bags is security. Otherwise, they are sort of annoying. Carbon ones may not be though as they are light and don't need to be reshaped after every ride..
I fully agree with your statement....and like to add the additional crash protection they offer the bike. I have been going back and forth before moving on this project. I had a set of softies on the bike....and it works great....and it would stay like that....if it was`nt for security.......and serving as crash protection...... That`s why I finally pulled the trigger. As with most projects I start.....well....complex ones.... I have a rough idea of how it is going to conform..... but with that in mind.....there is room to expand/change..... But the lid will, for now, be fastened with 3 snaps and one hinge......That`s all I have for now. I figure....I`l get the boxes otta production first...

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Old 01-20-2011, 08:45 AM   #84
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and how are going to get a good cosmetic finish on the outside?
Quote:
Originally Posted by ebrabaek View Post
I know several of you are waiting for this....... You will see.....



Erling
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I used to say "one day" a lot. But then I got scared I would wait one day too long. So I am doing it all now
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Old 01-20-2011, 09:01 AM   #85
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Wicked Final outside layer.....

So in order to satisfy your popcorn munchers........ box was brushed with resin......


Then a 44x 15 inch piece of CF was cut....so to overlay all but the top (pictured) This final layer is purely cosmetic.....there are already plenty of strength in there.
Wrapped it around....and had one seam in the back (inside) and a small on in the top left..... These will of course be sanded smooth...




In the oven for initial cure..... a few hrs at 90-100 deg.F. If you go straight to post cure @250..... The fabric has not set....and you will risk the CF becoming dynamic..( moving).


Onward we go with the other box......
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Old 01-20-2011, 11:50 AM   #86
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A few notes...... It does not matter how much experience you have...... The second piece will always be better than the first one........... Ohh... well... not really kidding here. As the first box came together..... I was not comfy with the patterns that was laid down..... thus stressing the material more than I would have liked...... No biggie..... You just stop before the last layer.....let it cure..... then sand it smooth...... But obviously it would be great if one could lay`em all wet in the first go. Well as history repeats itself with me..... That was the case with the second box. With the knowledge of the first go..... It all went down great in one take....and even still looks better than the first one..... Here is the second with all layers on......





There is still the seam in the back....and a very small one in the top left on the second pic..... but again...they will be sanded out......



Erling
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Old 01-20-2011, 06:11 PM   #87
HighTechCoonass
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How many hours of work and how much are the materials?
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Old 01-20-2011, 07:34 PM   #88
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How many hours of work and how much are the materials?
It`s still early in the project...... But I think the epoxy and Kevlar+ Carbon Fiber about $200 Out of that...there are several cut CF and Kevlar to be used for the next project....due to funky patterns..... Add perhaps $35 in hardware.... I`m expecting to be on the right side of $300 for both.... As for the labor..... So far....about 10 hrs..... give and take a few.... It`s time consuming...... And that`s where it`l pay off....if you don`t mind spending a little time sipping liquids in the garage......

Erling
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Old 01-20-2011, 07:35 PM   #89
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nice work love it . if you dont like the first child ill come over and take it off your hands no charge to you
It`s great to have friends....



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Old 01-20-2011, 07:50 PM   #90
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Erling you are a master!
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