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Old 04-11-2013, 12:03 PM   #1
ebrabaek OP
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Location: Grand Valley, Colorado
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Wicked How to make your own Carbon Fiber Clutch/Brake lever....

Soooooooo...... You wanna make one....ehh....... Well your in the right place . This project started out with a Rekluse clutch, that moves the clutch lever full out, thus guys with short fingers, will have trouble reaching..... no wait... you don't have to use the clutch.... but I will save that for another thread. I bought a PSR adjustable lever, which is great, but I wanted only a one inch throw with the new clutch, and no adjustable lever will yield that. So as it usually begins, I dove in. As many, that have followed my build threads realize, it is really sort of playing with play dough. Except this play dough is like a wet napkin...., but don't panic, even as not being a wet napkin juggler, you can still do this. Pssssstttttt..... any CF 8GS lever out there.....
As I have many how to vid's on my you tube channel, I enclosed the link to it here...

https://www.youtube.com/feed/UClrJqtAXv7r7E2VN4RxA_VQ/u

So here it goes. First you need to identify how you will do this, and as usual, I begin with making a rough mould, that I simply lay up the composite stuff on. I identified the shape I wanted, but the way of taking the stock lever apart.



Then from a 22 gauge steel sheet, I cut the rough out line that I wanted....



Began bending it into the shape I wanted.....





Then it was braced, so as not to move to much when my ogre fingers began laying the composites down....




A stand was made to hold it in place....



The the usual layers of release agent was applied ( 2)...



Then 10 pieces of 12 oz (6k) for the lever, and 14 for the cable hanger was cut, and all readied for the operation....



I put a few layers down on the table first to check the overlap...



Then it was on to the mould..... Not I bend the wings out to be able to lay it down....




Then after all layers are down, wings were folded back, and the u shaped rod was installed to hold it all in place....



Curing.....
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Old 04-11-2013, 12:35 PM   #2
runnin4melife
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Interesting! When you said that you were going to do this I imagined that you would rough it out with a metal frame, put a boat load of layers then press it with a backing to squeeze it down. Then once it is out cut/sand it into the final shape....
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Old 04-11-2013, 01:08 PM   #3
ebrabaek OP
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Originally Posted by runnin4melife View Post
Interesting! When you said that you were going to do this I imagined that you would rough it out with a metal frame, put a boat load of layers then press it with a backing to squeeze it down. Then once it is out cut/sand it into the final shape....
I thought of that, as well, but as this is unknown area of use, I wanted to align the fibers to yield maximum strength. Rather than only epoxy between layers holding down the torque.... I wanted fibers also..... Ahhhhh... The fresh aroma of baked polymers..... No wait... there are none...
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Old 04-11-2013, 02:26 PM   #4
ebrabaek OP
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Cured.... Mould coming apart....



Next to the mould, and original piece...



Note, just like grain in wood, the grain is visible in the CF.... Wait until it is polished......



More sanding, and very careful that is....



And more......



Thats it....



Then I wanted to add stiffness... Plenty strong. So prep for second bake...



Baking.....
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Old 04-11-2013, 03:50 PM   #5
ebrabaek OP
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Final rough in......



Tomorrow, finish sanding.....and fitting.....
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Old 04-11-2013, 05:29 PM   #6
JRose
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You take apprenticeships?

Seriously. I love the step by step instructionals. It makes me want to get some material and take a whack at it.

I've worked with Fiberglas in the past, but only very little. It was neat the stuff we could do with it.
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Old 04-11-2013, 08:43 PM   #7
ebrabaek OP
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You take apprenticeships?

Seriously. I love the step by step instructionals. It makes me want to get some material and take a whack at it.

I've worked with Fiberglas in the past, but only very little. It was neat the stuff we could do with it.
Thanks.....
There are a little differences between glass/polyester, and CF/epoxy, but the idea is the same. I encourage you to dab your hands. That is the exact reason I go the step by step tutorial. This is somewhat of an odd project, that arose froman angle I did not think of.... But it only took me about two hrs to get to this step. and the lever will cost a whopping $10 in material. Side benefit..... No more cold clutch hand in winter......
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Old 04-12-2013, 04:04 AM   #8
JRose
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Originally Posted by ebrabaek View Post
Thanks.....
There are a little differences between glass/polyester, and CF/epoxy, but the idea is the same. I encourage you to dab your hands. That is the exact reason I go the step by step tutorial. This is somewhat of an odd project, that arose froman angle I did not think of.... But it only took me about two hrs to get to this step. and the lever will cost a whopping $10 in material. Side benefit..... No more cold clutch hand in winter......
I would like to. I have plenty of time to mess with it at the fire station while at work.

I might get with you soon about where to get materials and such.
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Old 04-12-2013, 05:27 AM   #9
ebrabaek OP
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I would like to. I have plenty of time to mess with it at the fire station while at work.

I might get with you soon about where to get materials and such.
May I also suggest that you look up all the threads I posted here. It has a lot of general info, like materials....etc...
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Old 04-12-2013, 07:10 AM   #10
JRose
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May I also suggest that you look up all the threads I posted here. It has a lot of general info, like materials....etc...
Will do.
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Old 04-12-2013, 08:40 AM   #11
runnin4melife
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Jump on into it. It is a lot of fun. Also look at his YouTube videos! It is a great experience and don't get discouraged if things fail.
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Old 04-12-2013, 10:55 AM   #12
ebrabaek OP
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Originally Posted by runnin4melife View Post
Jump on into it. It is a lot of fun. Also look at his YouTube videos! It is a great experience and don't get discouraged if things fail.
Thanks for pointing that out Adam. First page has been updated with a link.
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Old 04-12-2013, 11:11 AM   #13
ebrabaek OP
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Then the rub.....and final cure....at 300 deg...




If it fails, I can tell you it is in the hole that the brass ring protrudes through...... We shall see in 45 minutes time....
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ebrabaek screwed with this post 04-12-2013 at 11:12 AM Reason: Idiot spelling...
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Old 04-12-2013, 12:10 PM   #14
ebrabaek OP
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Yay...... It works......
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Old 04-12-2013, 12:13 PM   #15
ebrabaek OP
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Hole cut to accommodate the brass sleeve....




Real bike porn.... Note the grains....



The stock lever it replaced in the front, and the CF in the back...



Carbon Fiber lever..





Now what to do with these......
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