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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 - 02/23/2018 : 18:59:30
I use 3 layers of mat over orange polyester tooling gelcoat to give it structure then i cheat with carbon or fg boat cloth over mat with epoxy. 1/4” flanges drilled and bolted.

Formula used: E over P always. (Epoxy over polyester). The big orange cowling mold i wanted to do orange because orange can be buiffed to higloss or repaired, sanded & buffed to higloss.

The black molds i make are black epoxy tooling gelcoat & carbon over that.
I always use 3/4 oz mat. Compositeenvisions.com

Matthew Martin: watch this vid again.



Matthew Martin Posted - 02/23/2018 : 18:53:04
Hi, you note that you use 3 layers of mat... is this 2oz mat? Is three layers of mat strong enough for a mold?
carolina Posted - 02/23/2018 : 18:39:07
Warren, built this for doctor w/750w bafang. It grows on ya.

Nice to have molds finished but I’ll keep making improvements/more plugs and molds. Somewhat addictive to retirees. Shop time! Gotta build me a unibody. Riding now in this incredible weather/80 everyday, nights are great. 4 wheeler has spoiled me, don’t want a trike.
warren Posted - 02/23/2018 : 08:14:03
Wow, you have a tail AND a top! It's starting to look like a real velomobile!
carolina Posted - 02/14/2018 : 16:07:23
A & B complete, now start C of 3 part mold: rear cowling.

1st of 3 coats of orange every hour then 1 layer of glass mat each day for 3 layers.

carolina Posted - 02/06/2018 : 10:05:04
Another plug started few days ago : this part will accept the 4 wheeler rear-end hardware in the carbon fiber velo unibody. Wheel wells, floor. Also will use HILGO rear shifter on order (not a conventional derailleur). 10 sp rear & pinion 18 sp at front.

5 pieces so far, 2 more.

8 pieces now almost finished to make 4 wheeler rear-end hardware plug. May finish in few weeks:


carolina Posted - 01/31/2018 : 11:36:30
New canopy look:

1) more pedal clearance
2) make windows at home & install
3) no oven windows/ great for owner repairs

Relaxing to layup this part last night. Mold turned out great. Majority does not want a canopy style velomobiel but l wanted one to ride all winter here with fairly mild winters @ night or day.

I think it looks good/favors the challenger velomobiel. And can install led brake lights atop the unit also.

Waiste part: above
Unit glues inside of cf canopy along with the 3 windows. Gonna build a seat lip on mold after i find scribe line with this test unit made with blk polyester and fiberglass. Next one for use will be 2 kinds of carbon with innegra imbedded in it.

[Finally frekote]


carolina Posted - 01/25/2018 : 22:31:52
Two and half hour layup. 5 & 6 layers of 11oz twill. Should be a nice window frame mold/tool.


carolina Posted - 01/10/2018 : 17:35:55
New plug to pull another mold.

This will make a 3 window carbon frame to install into the carbon canopy.

Out side is together now @ seams with bondo.

Will flip tomorrow and glass inside for strength.

This plug will be grey duratec and wet sanded hopefully in week or so.

Two different styles of windows in my carbon canopy up front.

Closer to pulling a mold from this plug too: sand and sand. Then polish.

Sprayed this first coat out in driveway today, now some fine tuning wet-sanding and then buff the polyester and pull a mold from this:


carolina Posted - 01/07/2018 : 12:29:32
Check out ovens in general topics for other parts of this velo.

carolina Posted - 01/07/2018 : 10:27:45
Started the split mold of fear cowling . Zoom in u see the 4 wheeler hardware from europe on my shop vehicle.

Closer: 3 part mold

Also will use this split mold below to make rear wheel wells for my 4 wheeler velomobiel unibody.

Brevity & misspellings rampant. (New lens in left eye/blurr)

carolina Posted - 12/11/2017 : 21:24:00
Sorry this gets boring but plugs and the hardest longest parts to finish in the industry. Large companies pay 125$ per sq foot to have them made & ready to polish.

i’ve learned that I don’t hate making plugs and a bunch of new techniques. Some of the next big plugs will be foam covered in duratec products. Type in fiberglast.com. & watch their YouTube channel.

From this to:



carolina Posted - 12/10/2017 : 13:49:57
Yes. Fg-innegra or cf-innegra. Mold ready in couple weeks or close. Conquered the sand buff tech of duratec sunshield & very happy. They hang below axles.

warren Posted - 12/10/2017 : 09:30:58
Very pretty! I may be hitting you up for some 20" wheel fairings!
carolina Posted - 12/07/2017 : 19:39:53

Now we have 20” front fenders carbon or glass. Nice plug now to prep for 2 piece mold/tool.

Alot of shiny work to only use one time. Still haf to wet-sand and polish:

Saturday: started the rewarding task a few days of wet sanding. 1000,1200,1800, this is a easy process & enjoyable. Buff with wizard next week and get another bottle of swirl remover. Nerves of a whore in church.


carolina Posted - 12/06/2017 : 22:12:36
Travis sprayed two plugs tonight with clear duratec.

carolina Posted - 11/27/2017 : 22:32:28
Duratec on youtube: when u have a mold you have a mold. Make as many part’s as you want.

I put duratec on the plug thick then sand and fill, sometimes twice.

I can spray final coats with harbor freight $14.99 gun smooth. The trick is for final spray coats are. Buy duratec thinner and duratec hi-gloss additive. Strain your batch add hardner and spray. Then wet sand plug hours with light paper. I have sand paper cloth backed up to 12 thousand. 1800 can get ya into the buffing area. Duratec buffs to 80%.

Use only “ tr mold “ release wax. Ebay.

I use only Wizards polishing compounds.

carolina Posted - 11/22/2017 : 10:24:42
Working on oven inside now. I can set inside and install adhesive. Windscreen acrylics (320 degrees F) and part curing (140 degrees F). Buying both polycarbonate and cell cast acrylic 16th inch to experiment with.

The door with 2 handles is a plug type door, push in/pull out with felt perimeter seal.


My method below except l use female mold: and 16th inch thick products. Do not drap over male mold.



carolina Posted - 11/22/2017 : 10:16:57
Built a 23 piece wood flange around cowling plug covered with fg. Grey duratec will go on top.



carolina Posted - 11/15/2017 : 17:25:35
Now i have it going on in true fashion up front on the macpherson strut and mag wheel. Waiting on new speed sensor cable. Magnet on inside front spoke of mag wheel. Lil polarized red light thing from bafang with two plastic ties mounts great on front strut (right side). USA invented macpherson strut from Chevrolet engineer /dr. Macpherson 1955 or so.


carolina Posted - 11/05/2017 : 19:02:08
Will i ever finish the windows and rear cowling?? Lol. Goes on & on.

Have bubble wrap on it. Velo with be wrapped at king sign company, it will be two tone yellow over black with some graphics.

Finally down to wet sanding grey duratec lightly to ready for clear duratec final coat in spray booth by a pro. Then some polishing and release agents application for mold.



carolina Posted - 11/04/2017 : 21:54:49
Wow, front saddle really tick, way many layers. Just fell off when i touched it with knife. Tick, really thick.

Custom belly lift saddles for velomobile. That’s beautiful like furniture lol, trim, sand, install felt.


carolina Posted - 11/04/2017 : 15:59:43
Just ongoing velomobile lift iam trying to perfect. Jack up a loaded velomobile with your foot and let it back down with other pedal.

Rear saddle turned out great, just add some felt. Finish front saddle tomorrow.


Older style lift (older photo), l keep mod’ing it,, ready for more mods over next couple weeks. Lay under velo with pad and pillow and adjust 6 tie-rods for hour and other stuff: my 4 wheeler up in the air, it has took me away from 3 wheelers. Best money l have spent in years (the quattrovelo rear-end) to learn about what ls handed down from the euro leaders.


Put in hot water heater today for dad,wwll vet of philippine islands. Now abc store for cherry vodka (kay) and some jackblack.

carolina Posted - 11/03/2017 : 19:13:10
2 saddles made today for my velomobiel lift.

Much fg,cf,soric honeycomb, glass mat, polyester.


Below you see soric honeycomb. White does not accept resin, the clear honeycomb shape does. Under ten dollars per yard, great around shop


Speedbiker Posted - 11/02/2017 : 22:41:09
You're in the home stretch. Keep after it!

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