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In this tutorial we demonstrate how to create a forged carbon fiber cured sheet with a double sided satin finish using non-porous Teflon coated peel ply, glass plates and vacuum bagging. The material used here is Gold Standard Forged Carbon Fiber Fabric, but this method can be used with any of our forged carbon dry fabrics.
0:16 Preparing Side 1
2:33 Preparing Side 2
5:10 Combining Sides 1 & 2
8:07 Vacuum Bagging
10:13 Removing Peel Ply
10:53 Finished Part
1. Forged fabric is cut to the size of the tempered glass plates using a rotary cutter. The non-porous Teflon coated peel ply is cut slightly larger to prevent breather cloth sticking to the edges of the carbon/glass.
2. Deep Set Epoxy Resin has been degassed in a vacuum chamber to remove air bubbles, and then a heat gun is used to reduce bubbles introduced during the application process. Amount of resin mixed for this project was approximately 1.2 x the weight of the dry fabric.
3. Glass should be coated with a release agent such as wax to protect against excess resin squeeze out.
4. Peel ply and glass must be free of dust when placed together as even a small particle between the surfaces will create a dimple in the finished plate.
5. This method generally yields a pinhole free, lightly textured surface. Surface imperfections can typically be avoided by thoroughly pressing/rolling the sheets before adding the glass backing plates. Also, reducing the vacuum level to approximately 8" Hg may reduce voids while still providing adequate compression. If necessary, imperfections can also be filled after initial cure by spreading a thin coat of resin over the surface, adding peel ply, rolling to remove air pockets, topping with glass and allowing to cure.
In this video tutorial we demonstrate a technique for skinning/wrapping the upper and lower grips of a car steering wheel using Premium Bold forged carbon fiber dry fabric. The method shown here does not require vacuum bagging. We also show how to fit the secondary grips with custom leather coverings.
0:16 Preparing Part and Supplies
2:32 Applying Epoxy Resin
5:08 Applying Forged Carbon Fiber Fabric
10:53 Finishing the Forged Carbon Fiber Surface
12:42 Applying Custom Leather Grips
1. We left the secondary grip covers in place until after installing the carbon fiber since they were to be discarded and replaced with new leather. If you wish to reuse any grip covering material, be sure to carefully remove all pieces before beginning the carbon fiber skinning process as resin may leak under the tape and damage the material. Any material left on the wheel may also be damaged during the carbon fiber trimming process of not first removed.
2. Carbon fiber dry fabric is cut larger than the template to allow overlap and ensure full coverage. Any irregularity in thickness due to this overlap is easily leveled during sanding the stage.
3. The double layer of forged carbon fabric is still very thin and should be sanded only just enough to smooth the surface and reveal the pattern. If the surface is sanded too aggressively and the underlying material revealed by mistake, simply use fabric offcuts to patch the area, allow to cure and sand to blend the area seamlessly into the overall pattern.
In this video tutorial we demonstrate a technique for skinning/wrapping a car center console using Premium Bold forged carbon fiber dry fabric. The method shown here does not require vacuum bagging.
0:15 Preparing the Part for Wrapping
1:19 Applying Forged Carbon Fiber and Resin
5:18 Creating the Smooth Gloss Finish
1. Existing cover, foam and adhesive are removed and plastic is keyed with rough sandpaper for a good mechanical bond. New foam is added to fill the top space. Foam is sealed with epoxy resin to created a surface suitable for skinning. Back of console is covered to protect attachment clips from unwanted bonding.
2. Forged carbon fiber dry fabric has been cut to size using the old cover as a template, and the clear film backing has been removed. Epoxy resin is spread onto a sheet of silicone coated nylon peel ply before placing the carbon fiber face down onto the peel ply. Additional resin is spread onto the back of the fabric to saturate the forged carbon fiber without damaging the Premium Bold pattern. A roller removes trapped air and helps to ensure complete wet-out. The console is coated with resin and then placed onto the carbon fiber/peel ply layup. It is then wrapped around the part using the peel ply to manipulate the fragile carbon fiber into position. Relief cuts are added to the nylon peel ply as needed to conform to the console shape. Long strips of plastic peel ply are used to tightly wrap the part and compress the forged carbon fiber against the console base. Tape is used to further secure the strips in place while the part fully cures. Alternately, the part could be vacuum bagged.
3. All peel ply is removed from the cured part. Edges are trimmed and the entire part is sanded with 220 grit paper to remove high spots, using the texture from the nylon peel ply as a guide to avoid sanding through the forged carbon fiber skin. To build up the cosmetic gloss finish, the part is coated with epoxy, cured and sanded. This process is repeated as needed until all low areas are filled. The part can then be further polished to a gloss finish or an automotive clear coat can be added for a full gloss finish plus UV protection.
Created 2 months, 3 weeks ago.
Category Auto & Vehicles
Luxury Advanced Composite Designs