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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. Ideas/conversations are welcome: march-7-2015 [This past MAY has been 2 years].

My molds favor this shape:

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 - 09/21/2018 : 09:05:02
I thought up a way to leave rear bulkhead original on the big unibody lower mold. The black roll-over mold goes to full canopy velo. The fglass one (plug) under it goes to man-hole top.

Standard velo upper/top. Man-hole entrance.


carolina Posted - 09/18/2018 : 11:35:35
See yellow fine line tape? Cut line.

Nail seated at rear for pulling pink tape.

Shipwrights divider and marker.

Its perfect and allowed 32nd of sanding on each half in future.

Not a laser culture shop here yet. No cnc too. Find the fault in the finished painted pieces.


carolina Posted - 09/11/2018 : 21:27:32
This yellow two tone is gone now.

Fitting man-hole top to lower: This top will be a plug for 1 piece mold. Will sit aside and layup lower unibody first, then start on top again.


carolina Posted - 09/09/2018 : 08:12:51
Video about: Mavcoat release agent on plugs molds parts. Most incredible! New chemistry coming along, hope it keeps coming.

Made this lil plug for roll-over behind head rest. This plug will help with new top project (indy car type man hole entrance on the velomobiel).


Large rain gutter, plug ready for bondo skim coat, sanding, & primer.


carolina Posted - 09/08/2018 : 13:22:58
Made a plug this morning 10:00 til 2:15. Plug wil temporarily sit into the big mold (above post). This is rear roll-over at rear bulkhead. Where front top meets rear of top at roll-over. Once plug is smooth a mold will be made from it that mates with big mold.

My cut line is rearward more than this line, this top will make a plug for upper top mold made later.

A whole top cut in 4 pieces is tedious to put back together. I had to put together original and re-cut at different location.


carolina Posted - 09/07/2018 : 07:51:31
Next project is new top roll-over at rear bulkhead.
1)I make a plug (master) roll-over with rain gutter down in the mold (one time use), it matches rear inside of new top.
2) Then lay the multiuse new top mold over it.
3)That mold will cleico on and off.
4) l will still be able to make other top (full canopy like yellow velo above) with it’s roll-over mold on shelf. Just clieco in place and go.


carolina Posted - 09/06/2018 : 10:52:06
Part removal from tools (molds) can be nightmare. This is new Mavcoat release agent. This is 3 part mold bolted together. Made a great rear wheel well system for 4 wheeler velomobile.


If you follow this thread u know this one took a while too. Hell, they all do but getting quicker and nice. Less headaches.


Trimming amateur parts is SOB, have a steady hand, i use 3 tools from harbor freight. They’re great. Long sleeve shirts, full face respirator, air-hose. I thru that shirt away today:)


carolina Posted - 09/05/2018 : 17:49:44
Top and rear of next 4 wheeler velomobile.


Flip top and glass inside tomorrow. THIS TOP WILL BE A PLUG, NOT A TOP. PLUG=MOLD=PART

This man-hole indy car entrance has to be in best place l can get it for seat and head, the front and rear of top will run-out at given locations.

carolina Posted - 09/04/2018 : 20:15:38
The heart of the 4 wheeler curing. 6 hours plus cutting patterns out. All carbon twill.


carolina Posted - 09/02/2018 : 16:13:54
Layed up one side of three part mold of rear wheel wells today in 2 & 3/4 hours. 4 layer sandwich of carbon only with inserts after second layer.

First layer is hardest, then second layer will behave and stick. Moving and seating the thicker carbon with the wonderful harbor freight gloves. Used slow hardner.

Last layer 25” X 35”, just barely enough.

Epoxy clear-coat up in the wheel wells and wax. Keep the road grim off wheel wells & its epoxy from tires. Otherwise epoxy would be suffering over time.

carolina Posted - 09/01/2018 : 20:15:27

Needed lil’ more cutting room, 2 Harbor freight stands, threaded rod, and some PVC. And stands can be used with the rollers they came with. With electric scissors and serrated blades (wish i had had in mid 90’s) its a good table. 3/8” sheet of plastic with worn numbered cutting pad under plastic. Some patterns are 50”x36” which is a yard from compositeenvisions.com. PVC fit perfect in the roll tube compositeenvisions uses. Rear wheel well patterns are 25”x36”.

Cheating 11 ounce twill carbon. Tape it then cut it.


carolina Posted - 08/27/2018 : 13:43:59
Notha short vid on my channel:


carolina Posted - 08/25/2018 : 18:46:52
Built this tiny 3/16 lip on brake lever. It allows stock micro-switch to remain stock. The thin lil’ metal lever on micro-switch is usually bent to some shape that will work. Now its out of box working.

Today i put 6mm rivnut in top of rear cowling. This makes it easy to roll velo around at rear with some hardware to hold on too. You can just keep inside or in your pocket.


CincyRay Posted - 08/25/2018 : 11:56:38
Nice job. Seems to me that If you want to start selling these without mechanicals, you would at least want to publish more ride info before you send it over to your first buyer. Why not put together a longer video filmed from a chase car to demonstrate what it can do. Is it fast or slow versus other commercial velos? How about having a more athletic bent cyclist take it out for a spin and see what kind of speeds it can achieve and how noises it is. How much does it weigh? How does it perform with and without the canopy? Is there a plan to look at internal hinges for the canopy? Sure would clean up the look. Thx.
carolina Posted - 08/25/2018 : 11:30:25

Been riden for year lol, got bout 15 different days. One thing paint don’t change. Page 3, pic shows 2017 November riding to grocery store or near that date.

Built the lowracer and 4 wheeler conversion too while working on this velomobile. [Glance over the 10 pages of this thread for quick timeline.]. Rode many moons without top or rear cowling. Wish post were numbered.

Velomobile delivered when doctor get back of 7th/vacation. Be watching the 4 wheeler velomobile build, started in above post. That will go lil’ quicker and the 4 wheeler mule has been riden about a year. Just moving hardware from old metal frame mule to new unibody. Save weight too.

Tom Schneider Posted - 08/25/2018 : 08:47:23
Now a test ride and results?

carolina Posted - 08/24/2018 : 23:26:45
Inside the WAW type rear cowling: i ran the rear lights cable with the cannon plug. The plastic weather guard is held on with “3M strip-calk.”


carolina Posted - 08/24/2018 : 23:20:36
Install windows with a few tricks:

Nuts, bolts, & hinges.


carolina Posted - 08/23/2018 : 11:09:29
Nowdays l can make a unibody ready for hardware and paint in 4 weeks of this full canopy style.

Soon l will start the regular man hole entrance velomobile top mold (posts above),,, when that mold is finished l could build one ready for hardware & paint in 15 days.

Hardware and paint takes forever. Builders can install their own styles of hardware and paint. I can ship unibodies cross-country.

Now your question: ripleys believe it or not:) ive worked every day including holidays and weekends for way over 3 years. Go to first post here on recumbents dot com.

I had 150 thousand views on bentrider before l was banner by brian. Those constant posts tell story from beginning. Recumbents dot com is best forum. Warren does not hate if your right wing constitutionalist, shoot pistols, reload ammo, hunt, fish, vote trump. If you were not born before 1953 it’s very very very difficult to know America.

Toecutter Posted - 08/23/2018 : 09:41:30
Beautiful work. Any idea how many hours of work it took to build?
carolina Posted - 08/23/2018 : 05:14:03
4 long years people:

the silver reflector DOT tape will go on both sides and rear later (same tape as on DF velomobile). That will really set it off between the two colors of yellows.

I like it, happy with paint job/2 tone. Doing accent stripe on both side and rear with reflective tape like on frt & rear of DF velomobile. Then it will look good and finished. Everything fits. 4 years of building molds and this great velo. Iam happy. Rolhoff and bafang 750watt up front. Great music with 4 exciters.

As seen in above post,,, already started second velomobile which is 4 wheeler. This one will be delivered to doctor next week.

carolina Posted - 08/22/2018 : 13:42:08
Priming windows to install tonight with DOW u-428 windshield adhesive. If you don’t use dow primer the plastic window can not hold over time with the dow adhesive. I scuff plastics perimeter and brush on primer.

Dow primer/ebay. If damaged windshield needs to come out, a wire will cut it out. I take stock caps off and find a tight top of something around the shop. That way the tube does not dry out. Figured that out the hard way.


carolina Posted - 08/18/2018 : 18:00:04

Was nervous trying mavcoat for first time. The test worked incredible, rubbed 4 coats on with lil square piece of t-shirt. The grey plug was only wetsanded and buffed. After curing over night i grabbed it with light pressure/1 hand, and the mold and plug fell apart on table.

The old saying “ to good to be true” ,, well this one is proven true. Mavcoat cuts out 5 days of prep work on big mold for one man shop like mine. [even with prep with old methods your part could stick but not with mavcoat]. We are seeing these new products catapult composite industry forward for pros, amateurs, and novice builders. Now that my test is complete, i will Spray mavcoat with my $14 top feed spray gun. 1.4mm nozzle/mavcoat washes out with alcohol.

carolina Posted - 08/16/2018 : 21:47:03
You’ve seen top and rear cowling above post. Heres last painted piece.


carolina Posted - 08/15/2018 : 20:30:11
Travis painted tonight, just sent a pic. Get it tomorrow night.

Quest color: RAL-1023 yellow.


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