CarbonFiberHowTo1

CarbonFiberHowTo1 - CARBON FIBER TUTORIAL Part I At Synapse...

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At Synapse Motorsport Inc. we are frequently asked to fabricate parts. Since there is a lot of interest in these techniques I thought I’d show a few techniques to help you along. This should take the mystery out of carbon fiber. This high tech material can easily be used to add that special effect to your car. The investment in materials is small and the procedures used do not require any high tech equipment. If you follow along you will be able to make your own parts. Any new thing requires some effort but it’s very easy. The best place to start is with rather simple forms and build up to more complex projects. In this book I’ll be taking you through flat forms to overlays. Flat forms- instrument panels, door inserts basically anything, which is flat. Your success here will introduce you to resins and how to handle carbon cloth. This will form the base upon which we build. Safety- the resins used emit fumes, which can be hazardous, always work in a well- ventilated area, and wear eye protection and an appropriate mask. Disposable rubber gloves are important.etc. This first part we’ll make is a flat instrument cluster panel. We’ve made several of these to hold boost gauges, air/fuel gauges etc. The design is simple and uses minimal material. For ease of forming I use aluminum.
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Any type can be used, just measure carefully to fit the enclosure and space your gauges in a pleasing layout. Attachment brackets can be made from the same aluminum and riveted with pop rivets.
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Once the center holes have been marked they should be center punched. Holes are drilled with a hole saw available at any hardware store. Several places have these cheaply Harbor Freight for one.
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Once the aluminum base is made and fitted carefully to your car opening sand the face side thoroughly with 100 grit sand paper. This is so the resin will adhere to the aluminum, it’s very important! After sanding wipe the aluminum with acetone. Now for a super smooth surface were going to use a piece of glass. Any piece of window glass will do. First wash the glass with Windex and then wax the surface with Meguire’s
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carnauba car wax. Any carnauba wax will work, stay away from silicones and solvent waxes. They can interfere with the resin hardening. On the glass outline the aluminum plate with tape, this will help to show where to brush the resin. Now we’ll cut the carbon to size. This next step is very important. STOP Before you cut your carbon cloth, outline the area to be cut carefully with ½” masking tape. The best tape to use is the painter’s masking tape, which releases easily. However, I’ve made loads of parts with regular masking tape. Just be very careful with the tape, if you overlap, the tape will stick to the carbon fiber and ruin the weave. You want to keep waste to a minimum.
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The purpose of taping out the cloth is to maintain the weave without distortion or fraying. By following this simple method you’ll keep your carbon pattern straight and will waste
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CarbonFiberHowTo1 - CARBON FIBER TUTORIAL Part I At Synapse...

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