Carbon Fiber Climate Control Surround

Carbon Fiber Climate Control Surround - DIY Carbon Fibre-...

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DIY Carbon Fibre- overlay an Audi C4 Climate Control Surround Instructions –D. Forgie Mar. 18/08 The intent of this DIY is to give you enough hints so you can produce this: From this: To this you will need the following supplies: A C4 Audi automatic Climate Control (CC) surround, either wood (elm or walnut) or black plastic, e.g. 93 S4. Carbon fibre (CF) cloth approximately 8” x 14” (you need to use a piece larger than the surround by about 1.5” all ways) Sandpaper 80 to 120 grit to roughen the surface of the surround
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Isopropyl alcohol and/or solvent to clean the surround of any waxes or silicone or “ArmourAll”, etc. Fibreglas resin that is intended to be non-yellow, e.g. Fiber-Tek Surfboard Resin (500 mL or 1 L) Sufficient appropriate catalyst (to be added to resin at 10 to 15 drops per ounce) 3 Mixing cups (I got wax paper cups with measuring volume marks from the resin supplier for free) Wooden stir sticks 3, 2” wide hog-hair (cheap) “paint” brushes (these will be consumed/wasted, one per coat) Masking tape, e.g. ¼”, ½”, 2” A cardboard softdrink or beer “tray” with a 2” lip (the thing 4 six packs comes on) Wax paper Disposable gloves, e.g. blue nitrile Disposable particulate mask (under $1 at an Autobody supply store or NAPA, etc. don’t use a cheap one) Wet and dry sandpaper, 400, 600, 1000, 1200 and 2000 grit (2500 too if you can find it) Cutting tools, e.g. Dremel with grit disks or Xacto™ modeling saw 8 inch single bastard metal (and plastic and wood) file – e.g. from Home Depot, Rona, Lowes, etc. Small non-tapered, straight, round file Polish suitable for clearcoats Car Wax Black Felt pen Step 1: Prep the surround You want the surface of the surround to be clean and a little rough. So wipe the surround with solvent and alcohol, each twice. Sand the surround surface with 80 or 120 grit sand paper to roughen it up to provide something for the resin to bite onto. Wipe the surround with an alcohol soaked clean rag (or paper towel) one more time. Blow any residuals off the surround Tape the outer and inter edges of the surround, as shown in the photo. Keep the tape back from the outer surface of the surround by about 1 mm or 1/16”. (The purpose of the tape comes later when you are cutting the resin-soaked (and cured) CF away from the surround) Photo of the prepped surround with tape on the edges:
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Step 2: Prep the Carbon fibre cloth Select a piece of carbon fibre that has no flaws and will be about 1 to 1.5” wider and longer than the surround on both ends and top and bottom edges (i.e. 2” to 3” wider and longer than the surround itself). Consider how you want the “grain” to run, i.e. the diagonal running down left to right or up left to
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Carbon Fiber Climate Control Surround - DIY Carbon Fibre-...

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