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  #1  
Old 07-28-2014, 07:34 PM
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Default home made carbon fiber dust caps DIY

thought id toss together a little DIY for people that may want to try it out for the fun of it. making your own carbon fiber caps. while it may not be the most fun, its cool as hell to see it finished and you can pick your own material.

to start-

safety-
  • well ventilated area, high on fumes -> brain damage
  • 75 degrees + -> cures faster
  • gloves -> its sticky stuff
material list-
  • gloves
  • paint brush, preferably 2"
  • carbon fiber fabric
  • decent painters tape
  • resin and hardener (Wal-Mart)
  • mold of some sort
  • mixing tray/bowl *not foam
  • sharp scissors
  • mixing stick/mix utensil
  • the pink bondo spreader is to straighten the weaves in the carbon fiber, not completely needed
first, gather all your supplies

decent pair of gloves to keep the resin off your hands

a paint brush that's not foam, 2" works well

carbon fiber of your choice, any kind

decent painters tape, not clear tape or duct tape

resin and the provided hardener, it was ~$20 at Wal-Mart in the audio isle ish area

mold, an old dust cap that's smooth will work, as long as there's no paint on it.

mixing utensil, I used a plastic knife

mixing bowl, not made of foam. it will eat it/melt it

sharpest scissors you have lol

----------------------------------------

go some where there's good air movement and its 75 degrees plus (above or below is fine, it'll take longer to cure if below 75)

lay out all your materials you'll need. look at it.............. stop



unroll some fabric, enough to do your cap plus some



place the part on and lay tape about an inch from all the edges so theres a little carbon fiber extra


then cutout the fabric, cutting in the center of the tape



at this point use your finger to straighten any messed up strands in the fabric so there all as straight and smooth as possible, then set it to the side carefully

clean the molds surface, there should be no paint or It will pull the paint after the resin eats it alive

then pour some resin in the mixing container. a little extra is better then not enough


I used about a half cup of resin... then added 6 drops of hardener. too much will cook/crack it. too little and itll just take longer to cure






stir it a lot, nice and slow figure 8 is fine. don't be shy to take a minute to stir




then apply a nice thin coat... be thorough, make sure you coat everything


next part wasn't pictured since I was born with 2 hands... hold the fabric over the mold and start sticking the fabric in the center and work your way out. do not start on the outside. touch in the center, drag your finger gently outward

this ^^ would be the dry look, if you plan to try that, thin coat on the form or it will bleed thru.

now coat the cloth very gently with a nice thin coat... go with the grain ( the same direction as the lines) not too much or itll pool, you can always coat a little more later if needed . coat beyond the edge of the mold, itll save you big time when you clean cut it later on

drag the brush gently across the coats after each application to get any extra off








more to come when mine cures

if you want thicker caps, repeat the steps again
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  #2  
Old 07-28-2014, 07:40 PM
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Cool idea
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Old 07-29-2014, 12:42 AM
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and the finishing process ( you could hit it with a ton of clear if wanted)

first, leave it in the mold, I acts as a nice pattern to follow as you cut. I like to start by trimming the bulk away then the smaller





then trim around again getting nice and close, take your time


and done
[IMG][/IMG]

now mold release
diy carbon fiber caps - YouTube

this is the back impregnated with resin...mmmmmm

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Old 07-29-2014, 12:51 AM
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looks great, how do these compare to the DD caps
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Old 07-29-2014, 05:46 AM
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Quote:
Originally Posted by radiospank View Post
looks great, how do these compare to the DD caps
DD will be better which is t be expected of a long time established company..these come out good looking and strong
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Old 07-29-2014, 07:42 AM
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Thank you sir!!!
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Old 07-29-2014, 07:46 AM
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Outstanding. I've been needing some 3'' caps and nobody makes them.
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Old 11-11-2014, 01:58 AM
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how does the weight to strength ratio compare doing it this way vs a poly cap

how many layers are needed to make it stronger
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Old 11-11-2014, 04:38 AM
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Strength of one layer is slightly more then poly with equal to slightly more weight due to resin. 2 layers criss cross would be pretty strong once glued to a cone
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