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 Carbon mold/tool for lower&upper enclosed velo

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carolina Posted - 05/15/2014 : 12:24:23
How l started. My airplane molds (BD-5) l own are used for cf velomobile unibody shell. Ideas/conversations are welcome: march-7-2015 [This past may has been 2 years].

My molds favor this shape /a pic from google:

Rear cowling will look like this photo below, my velo at rear is 5" wider: plus i have a rear bulkhead like the WAW velomobile.


brevity&misspelling rampant
25   L A T E S T    R E P L I E S    (Newest First)
carolina Posted - 10/20/2017 : 22:24:03
Rubber perimeter molding around longerons areas came in, l love it!



My friend ray and l have paid some learning curve BAFANG dues for many months. Its paid off now, i turn the wrenches and order stuff and ray does all the wires and laptop work. I sent to vegas to have soft-start firmware installed @ lectric-cycles/the erad people.

I tried to talk customer out of a bafang, glad i lost because l like the bafang alot and have learned much. The bafang is a rewarding option. It has its uses and will be needed over next 30 years of infrastructure in usa of bikeways for the masses.


carolina Posted - 10/11/2017 : 11:38:22
Still on rear plug (the rear cowling over rear tire behind bulkhead), big project for two piece mold. Worked on belly of plug forever.

1) bondo
2) 2 kinds of duratec
3) wood structure inside
4) fg , soric, and epoxy filler
5) used 2 pieces of an old rear cowling to make new plug
6) plug=2 part mold=carbon part.

Have some good tools and techniques out in the driveway now and tomorrow some great weather coming for 8 or more days.


carolina Posted - 10/05/2017 : 22:22:14



carolina Posted - 10/05/2017 : 20:12:18
Also had to correct part of the unibody mold at rear:



carolina Posted - 10/05/2017 : 20:08:52
Forever on the rear cowling plug,, at least l have the belly of it finish. Its been a huge chore.



carolina Posted - 09/27/2017 : 16:31:26
Thanks Grant! Now I'll come over there and hassle ya:)

Grant-53 Posted - 09/27/2017 : 16:18:23
I started a thread under Electric Velomobiles as requested. I don't sit up nights thinking of ways to be hard to get along with...it's just a gift. Sorry we couldn't make a trip to NC, the old van protested too much.
carolina Posted - 09/27/2017 : 12:33:31
Grant, erase your post off my thread. If you want to talk about your politics start another thread.

I work to keep this thread up for people who want to watch a build. Start your own thread, i will be glad to come there.

Grant-53 Posted - 09/27/2017 : 10:21:49
Removed per request
purplepeopledesign Posted - 09/27/2017 : 01:29:10
Removed because quoted post also removed.
Grant-53 Posted - 09/26/2017 : 22:08:56
Removed per request.
carolina Posted - 09/25/2017 : 21:31:12
Motor came back from vegas this afternoon with new lil display unit, that was all that was wrong. And a setting that only can be done by them i opted for: "soft start".


Bafangs R here to stay for the masses and these vehicles.

carolina Posted - 08/26/2017 : 09:51:54
Working on inside of plug for strength, then flip and bondo.


Iphone lens choice has no justice , my very first lens was best.


carolina Posted - 08/19/2017 : 19:41:45
My Velomobiel is 8&1/2 feet 106", dfxl is 103.5". DF is 102".

carolina Posted - 08/12/2017 : 09:00:27
Starting rear cowling plug:


Old cowling cut in half to mount on wood, then bondo in filler areas:


carolina Posted - 08/06/2017 : 09:59:11
Seat did turn out great, right flex and weighs nothing, twin layers of 11 ounce twill with compositeenvisions.com epoxy,, medium hardner.


carolina Posted - 08/05/2017 : 13:27:50
Just finished my first seat with this new mold. Bout 45 mins. I will razor cut perimeter later tonight at the perfect cure time. Carbon sands like a dream. Lol, l worked on this plug and mold forever.

Just trimmed scrap cf excess off (8 feet) now, the epoxy was perfect, cut like butter: see the hook blade l use. I waited bout 4 hours for the medium hardner/this is epoxy, not poly or vinylester from compositeenvisions.com


Saves a bad mess Monday morning after full cure. Just wet sand perimeter after full cure. Same with most all molds.


I am using quest seat but this new seat is stretched for two wheeler and my mule 4 wheeler shop velo. I actually rode the plug before l pulled a mold from it.


carolina Posted - 07/28/2017 : 18:54:24
Mods to rear frame:


carolina Posted - 07/22/2017 : 19:38:02
I could say l never need a trike again ever. Been riding today for first time, 7 day build. Two of those on composite piece behind seat. This is money well spent and a great design from the netherlands.

This will be a great unit in my cf velomobiel photo post above.


carolina Posted - 07/22/2017 : 05:31:55
This 4 wheeler has pinion up front zoom in. This is just the shop mule that l cut and weld and make changes and learn different stuff.
The bafang is on this one below: bafang's go on boom or rear wheel, check out YouTube if someone is interested. Bafang is interesting in velomobile below for running round town.


Grant-53 Posted - 07/21/2017 : 07:54:15
Looking great! Given our current state of DMV classes here in NY I could readily build a four wheel electric velomobile and call it a limited use vehicle (top speed 40 mph). Potentially a 500 mpge electric hybrid with a good aero package.
warren Posted - 07/20/2017 : 17:28:22
Looks heavy duty! Where are you putting the e-drive?
carolina Posted - 07/20/2017 : 12:05:56
Went together quick painted, new nuts & bolds on unit. Watching epoxy dry for vertical rear seat mount, chain wheel, grocery hooks, etc.. May build a pick-up truck bed on back.


carolina Posted - 07/19/2017 : 15:02:53
Watching paint dry and resting:


carolina Posted - 07/17/2017 : 18:02:39
New rear end on shop mule: NOT A THREE WHEELER ANYMORE.



Seat mold turned out good!


Working on canopy for a while:


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