oil pan 4

iTrader: (1)

Ok I have been reading up on forming composites.
I am only realy looking at vacuum forming. Becasue it can be made thiner, stronger, lighter and with less resin.
I also read that there were a lot less fumes form the curing because it is all contained.
I was going to start working with Carbon fiber, kevlar and hybrids of the 2.
I'll need a real strong vaccume pump and all the other stuff.
I was going to start by vacuuming forming them to a flat surface then bends and corners. Then on the more complex surfaces and more complex structers.
Any one work with this kind of stuff?
I want to use epoxy, because it is just about the strongest. Any one know any thin extreamly strong epoxys?
Does any one know of mixing composits with metal mesh, like Titanium or steel mesh?

JPrevost

The best CF is vacuum bagged with lots of pleets, checked for leaks, and then autoclaved.
The vacuum pumps can only do like 15psi but when you have 15psi of vacuum and 60 psi of pressure outside a delta of 75psi. That's the beauty of the autoclave. Parts come out with hardly any left over resin.
Ah, that brings me to my next point. You can not and shout not use anything other than CF resin. It isn't any more expensive than fiberglass resin.
You can mix CF with any other metal so long as you aren't using an autoclave. Metal expands more than CF, you'll end up with a mess and incorrect dimensions.
To gain tortional strength there is honeycomb matrix of varied thicknesses. I've only used 1/16" plastic, 1/8" plastic, and 3/4" aluminum.
The honeycomb is flexable so it'll form into curves. This is the best way to increase the ridgedness of flat CF, I highly recommend it's use when there are 3 or more forces on the part. Parts that wouldn't need it; side fenders, brake/intake ducting, diffuser, fan shroud, and seats.
If you just go with a vacuum pump setup, be sure to use thick cotton all around the part and imbetween the bags. It's kind of hard to explain through text so I'll post some pictures in a little bit.
CF is cool stuff but wow is it expensive and time consuming. Most things can be made out of fiberglass to save money. I'm suprised there aren't more real CF intake systems out there. You always see polished aluminum cold air but rarely see CF

oil pan 4

iTrader: (1)

I was going to use epoxy resin that is all I can realy use. Called system 2000 epoxy.
I was told that if I don't use enough resin that the part would be dry with resin and weak. And that the idel mixture is 44% resin and 56% fiber.
Any thing with less than 40% or more than 50% resin is less than good. From what I have been able to find.
I want to be able to make hollow structers like tubing and maybe intakes.
I don't realy have any idea how to make complex bags.
But I want to learn.

Morley

Work with it everyday in aircraft applications.
The "best" for this kind of work would be Epon 828/DTA
If you put any metal in/on carbon fiber it must be a corrosion resistant steel alloy, ie; stainless steel, titanium, inconel...etc.

Edit: The carbon fiber causes plain steel and alum. to corrode at an accelerated rate.

oil pan 4

iTrader: (1)

Thanks, I will see what I can find on that resin.

FSTFBDY

iTrader: (33)

exactally what the other 2 said.

I'll toss this up for you also...

http://www.fibreglast.com/phpBB2/ind...0e340842924966

Its a good site to read up on.

oil pan 4

iTrader: (1)

Yes, i have been over there for some time now.

91DropTopTA

There is a great tech walkthrough about CF fabrication in this months Issue of Grass Roots Motorsports magazine. It's an SCCA etc. type racing mag.

406TPI

iTrader: (1)

I use West Systems Epoxy, it works really well plus it's offered in many configurations.

JPrevost....vacuum is measured in inches of mercury Hg not psi for what it's worth

JPrevost

lol
Well the autoclave we use (both custom made by the shop owner) has apsi on everything. So when I say 15 psi of vacuum it's the same as saying 0 apsi, or -15 psi, you get my drift. Yeah, the industry uses in.Hg, doesn't mean I have too

fireturd350

iTrader: (8)

Actually I've seen it both ways depending on the website I was looking at.

oil pan 4

iTrader: (1)

Some companys let there molds cure in a pressure vessiles.
They make every thing PSI when they do that.

Dewey316

http://www.icancomposites.com/forum/viewforum.php?f=4

They have a lot of good tutorial information on composites there. I have also heard many good reviews of the video series offered by FiberGlast. I'm at the same point you are, I have been doing lots of reading and research, and am getting close to getting started with this stuff. I and my car have gotten to the point where the parts I want/need just aren't made. So I get the joy of trying to figure out how to make things.

oil pan 4

iTrader: (1)

I have some stuff on the way to start forming it.
There is a roll of carbon fiber on the way to me.
I have a gram scale that should be here any day so I can weigh the CF to know how much resin to use got it to ballance rods and pistons too.
I'm looking at geting a laser temp sensor gun so I can cure it at higher temps with a heat gun and for welding preheating.
I still need to get a vaccum pump and a few $100 of resin, vaccum baging stuff, mold wax, release agent and some odds and ends from fiber glast.

Dewey316

Let know how it goes when you start getting things going. I think you are a bit ahead of me, as I haven't yet started to gather materials. I'd be interested in the obsticals you have, and the products that work well for you.