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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:


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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.



velosRus.com
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brevity&misspelling rampant
25   L A T E S T    R E P L I E S    (Newest First)
carolina Posted - 04/19/2018 : 15:48:11
Ran out of black primer. Wet-sanding for wrapper guy. Bunch more touch up wet-sanding.


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velosRus.com
carolina Posted - 04/17/2018 : 20:16:48
Forgot to paint roll-over in prep for wrap:



Love this pic:


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velosRus.com
carolina Posted - 04/16/2018 : 09:15:55
Top and rear cowling fitting:


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velosRus.com
carolina Posted - 04/11/2018 : 10:18:54
Another tag team match with the plastic wedges and putty knife on the mayflower blanket. Plastic wedges & I won! Kevlar/fglass rear cowling held with 2 fingers. Will the customer mash it in:)

Wet sand, spray thin coat of that blk paint on lower velo, wet sand again and then fit with rivnut kit & screws to rear bulkhead . Trim jig for rear wheel.


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velosRus.com
carolina Posted - 04/11/2018 : 08:47:40
Monday i bought petg for side windows and its great fit with no warping



Also finished 3 window frame for front with polycarbonate and DOW u-428. Water-proof and want come out but easy to replace if damaged.


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velosRus.com
carolina Posted - 04/08/2018 : 18:39:44
Even patterns cut, took 6 hours. Second one l made, kevlar and fglass. Some carbon around perimeter.. Orange is peel-ply, will cure for two days.



I needed lil thicker fglass and lil thinner kevlar. Next time i will use 2 large pieces of each and trim the waiste for something else. Will be much quicker. Getting good at spraying duratec sunshield.
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velosRus.com
carolina Posted - 04/06/2018 : 17:57:44
Cutting kevlar: 1/4” fine line tape, tape wets out. Zoom in,, see blue tape is 95% cut off. CUTS LIKE A DREAM SUPER STRAIGHT. Use clear masking or fine-line tape if ya find some.

Like WAW rear cowling: gelcoat, (i use duratec clear) then thin 1 layer of fglass, then 1 layer of kevlar. Thats it! Super strong and light. Mold prep is: frekote, 7 coats tr mold release, then spray coats of pva mold release, then duratec sprayed and allowed to dry completely before fglass/kevlar.




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Duratec make everything easy and saves so much time preparing for paint or wrap. Not using gelcoat.







velosRus.com
carolina Posted - 04/04/2018 : 18:59:26
All day today I prototyped a way to install long side windows.

Monday, will buy thinner petg 0.30 for side windows. The polycarbonate 0.40 is to stiff for side windows.

Will use 0.30 polycarbonate for front next time.
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velosRus.com
carolina Posted - 04/02/2018 : 18:04:26
Ran a test from duratec reps. Oh yes, another world. Using duratec instead of gelcoat.
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This scrap test mold I sprayed with poly vinyl alcohol then 6 coats of TR mold release wax from ebay, a industry standard.



This finish is all i need:



Two small test pieces: one fglass kevlar & the other is 11&7 oz carbon fiber.
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Well that is bat**** incredible! Best camera i have.
1)PVA
2)6 coats of TR
3)duratec sunshield & higloss additive
4) one kevlar & fglass
5) one cfiber
6) epoxy from composite envisions

Thanks much guys: when u take a novice and help em, its your most reward as time passes.
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Getting close to finishing primer and wet sanding upper: bubble wrap off soon.



Wrap is not vinyl as you think, its super thin. Will show a hair.
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velosRus.com
carolina Posted - 03/28/2018 : 09:04:27
One person system to wrangle this 8 foot snake. This polycarbonate 4x8 foot sheet was 75$ out the door.


I got a system. See the padded fender stand bumping up against the sheet?,, gotta have that to hold it/scratch proof. (2) ya gotta hav the orange tube taped full length/step 1. The 9" long reach blk clamps on orange tube at both ends. This sheet is 8' long.



1)orange tube fglass came on
2)buy large handle cutter/scribe for plexiglass @ Home Depot
3)6 foot metal ruler
4)9” long reach clamps /Black in photo from harbor freight.
5)padded stand to hold plexiglass roll up/Harbor Freight.
6)poster board patterns.
7)leave mush as possible of white cover on plexiglass till mounted in window frame.
8)this polycarbonate is good stuff. I found hour away.
9)have enough to do another velomobiel @velosRus dot com
10)only way to cut compounds curves on thin plexiglass. (Vid below, best ive found).

https://youtu.be/XPlbZdwQ2AM
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velosRus.com
carolina Posted - 03/26/2018 : 18:51:09
Installed the rubber on the door jam with windshield adhesive.




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Now I have to micro, primer, & wet sand the top. Two-tone vehicle will be an easy wrap @ king signs co, it only 6 pieces.


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velosRus.com
carolina Posted - 03/25/2018 : 13:05:08
One unibody ready for wrap and hardware: buy your own hardware like i do and install on your own time snd money like i have in my cf unibody. Sold this one, gotta make another. Love it.

Daily:

Rear cowling takes 2 hours to lay up/2 layers. 20 mins to trim. Then spray primer. Then drill and fit on velo with pop in rivnuts. Then lite prime one more time & wet sand. Then it's ready for wrapper.

Gotta cut 5 windows out of 4x8’ (piedmont plastics $75) sheet this week. A enjoyable job. Not hard.

Clieco Windows in with double sided tape. Then shoot inside perimeter with DOW U-428. Then its water/storm proof but so simple to replace a ruined window. Just cut out with blade, clean and repeat. Polycarbonate or petg could get scratched.

Carbon canopy frame 3 hours to layup. All parts have 1 to 2 days cure time. Fitting frame & canopy to lower is 4 days casual while doing other stuff.

I can make a blk carbon canopy and three carbon “window frame” at nite after 7:00 casually/3 1/2 hrs. Cut lines are scribed into mold. Trimming is a pain, at least 2 hours morning time with wet sand & clean up.

The lower takes at least 5 or 6 days the way i do it. I can stop as i go with peel ply. Carbon & innegra only.

Seat, rear wheel well, and bridge in 3 days including cure.

3 piece frt boom parts/3 days including cure.

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Canopy hardware took a week to design, collect, & install.
Have tested driveline hard with 750watt bafang and also with soft-start firware turned off, no problem, 10 mm chain wheel axles from df. Tested over 16 days.
________________

I held phone correct, can’t figure new iPhone x: love the sound system in this velo.

https://youtu.be/lsC9RAnSpdE

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velosRus.com
carolina Posted - 03/20/2018 : 09:15:48
tonight: i will route front cord like challenger, up and over ww, driver can tie off with right hand (zoom in on blue cord, i have pulley that goes in frt.)
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I like the tilt-over canopy like the challenger eu velo. Easy off for maintenance or ride with top off if needed. No leaks on this canopy with heavy downpours.

Enter/exit right/USA. (Unibody velo)


Challenger velomobile: europe (shell on a trike velomobile)


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velosRus.com. 18283
carolina Posted - 03/18/2018 : 14:43:11
VERY HAPPY WITH THIS FIRST TEST PART:
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Test cowling turned out great, popped out today and learned what I needed about the mold. I wrestled the 3 pieces and won again. I use plastic wedges from Harbor freight and blow 100 psi down in there too for release. This was cheap one with polyester resin, fglass, some left over kevlar pieces.

This waiste piece is one of the 8 pieces iam useing to try to make a “plug” for rear 4 wheeler wheel well set. Went out on a limb a lil and used frekote only with no tr wax. It came out, but next one that is carbon/innegra and epoxy resin. l will use frekote and TR mold release wax.

REAR COWLING FOR MY VELOMOBIEL: (1st test part).

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velosRus.com
carolina Posted - 03/17/2018 : 18:21:02
Spent 6 hours on this today. Made a rear cowling for me to use in shop for mock up. Trying to make a 8 part plug that will become one plug for the four wheeler rear wheel wells unit. Then make a 2 part mold i hope.

Taped up flange for easy clean up.



Used polyester, fglass, & some kevlar.


Polyester resin mixed with black color additive and duratec higloss additive too.
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velosRus.com
carolina Posted - 03/16/2018 : 21:09:03


14 sp, 750w, iTunes, usb, led greatness, warm & dry.
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velosRus.com
carolina Posted - 03/16/2018 : 10:36:56
Seat view:




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velosRus.com
carolina Posted - 03/15/2018 : 18:15:50
New polycarbonate i will try. Five window canopy. No heat for now. Thinner and flexable polycarbonate.




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velosRus.com
carolina Posted - 03/13/2018 : 13:10:20
Got’er done! Wheels & foam bumpers:)



Need to make a couple parts soon, mold is frekote’ed!
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velosRus.com
carolina Posted - 03/11/2018 : 22:37:21
Yes the innegra is sandwiched in between of cf or fg.

The mule I built is 4 wheeler now with pinion 18 sp trans, SRAM 10 sp at rear. I love the rear-end allert invented in the Netherlands over a year or so is incredible w/mini air-bags, differential, and all.

Please start a thread here below me and Terry for your beautiful Mulsanne velo. We are glad your here indizzy. Everyone will wanta see inside and out of your velomobile.
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velosRus.com
ibdizzy1 Posted - 03/11/2018 : 22:11:12
OK. I got registered! Carolina, your canopy is looking great since I last saw it! When you use innegra, do you layer it top and bottom with something else in between? or do you have a single innegra layer in the middle layer with something else above and below it? I'm curious about what you have found to be the strongest most durable way to layer it?
Great progress you are making! Four wheels for traction and stability! Wow!


Dan Isbell
carolina Posted - 03/10/2018 : 15:28:29
Made new carbon window frame with twill,uni,innegra & some peel-ply in a few places. Polycarbonate windows going in later.


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velosRus.com
carolina Posted - 03/04/2018 : 17:01:54
Rodeo! I won!



Got lucky, nice 3 piece split mold, No blemishes or bad areas in 3 pieces. Some wet sanding and polishing of orange tooling gelcoat. That mold took forever, was not expecting that. Alot of work. Quicker way would have been the blk epoxy tooling gel & carbon. And flange fences are pia.



Will take few days to prep mold for 2 layer part w/innegra. 14 layers of release (3 cans) agents. Not including buffing. Trimming & sanding flanges outside in monkey suit big pain.

Current photo:



Getting ready to put legs on mold:




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velosRus.com
carolina Posted - 03/02/2018 : 17:01:02
Velomobiel riding.
https://youtu.be/-hUVeMtgY_g

velosRus.com
carolina Posted - 02/28/2018 : 18:26:23
Finally getting close to finish. 3piece split mold. I finished 2 other molds, started another complex mold, and mod’ed my lowracer while still trying to finish this mold. Huge project.


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velosRus.com

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