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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 - 11/12/2018 : 16:38:35
Installing rear WW’s.

Quest and DF four wheeler photo:


carolina Posted - 11/10/2018 : 16:47:30
Working on fit at rear. Four wheeler WW’s going in and body work. Wheel base 46 inches.

Last night and lil today: measured, drilled, & cleico’ed rear 4 wheeler unit in.


carolina Posted - 11/08/2018 : 11:48:47
Well, here i go trying to put these pieces together. Top pieces will be a plug to make a mold. Rear WW unit setting there to be fitted. Its a unibody so there is body work much.

Top is down forward, (top plug is 4 pieces with some bondo, foam, wood, & much sanding) can’t see in most pics. And i have pedal clearance. Will be riding it topless and no rear cowling for a while.

Brevity & misspellings rampant

carolina Posted - 11/07/2018 : 21:21:46
Thank heavens for mavcoat release. World record holder solo, yep l gotRout by myself. I owe it to Mavcoat release. If ya like watching wrestling, ha,,, thats like what it is. I did learn some stuff/tricks for next time to ease release.

Well you’ve seen the rear ww’s up above, they will go in the rear of this blk carbon unibody.. When i get better there will be less waisted time doing light body work on outside of these unibodies.


carolina Posted - 11/05/2018 : 20:52:22
This is 4 wheeler: pop out of tool this week later, try to make a vid.


carolina Posted - 11/01/2018 : 23:15:37
1st layer of rolling chain canal. Have a seat with peel-ply.

Yellow Dacron peel-ply is so wonderful. Throw in the garbage next day & keep rolhoff’ing.

Only rear bulkhead to complete:

Brevity & misspellings rampant

carolina Posted - 10/31/2018 : 15:43:42
More pics of unibody. Floor and rear vertical bulkhead left. Then let cure.

Did left & right rear walls today.

All the hardware from this will go in carbon unibody, then heavy frame an fenders in storage.


carolina Posted - 10/30/2018 : 15:27:19
Just for this nose area in front of wheel wells. The rest is more forgiving going reward.

5 hours, tough work! Twill (2), uni, innegra. Did learn couple techniques that will save me on next one. Thats just the way it goes.

FLOOR/chain canal last.

carolina Posted - 10/27/2018 : 17:06:40
Amateur carbon layup/2nd velomobiel:

Nice one piece front wheel well layup, some hardpoint locations are 4 layers (seat mount & vertical layers for Macpherson strut). Takes at lesst 3 hours to cut patterns, carbon and layup. By myself l use peel-ply to stop and start another day. Do other ww soon. WW’s are worst part. Quattrovelo uses 5 women to do the unibodies layup, i need 5 women.


carolina Posted - 10/25/2018 : 08:38:07
Been working on experimental plane i have for sale. After this 4 wheeler is completed l want to build another small plug and mold/tool. My rear cowling is removable and i want the front removable so if wrecked in front or rear hopefully the whole velomobiel is not damaged. Just replace front or rear. Like the waw, it makes for ease of transport. Well, it’s something to thing about.

1)No soric, no density foam in velos.
2)cutting some patterns today.

I use 4 kinds of carbon:
1)11oz., twill
2) uni, looks like a wooden deck all in one direction.
3) 7oz. Twill
4) thick biaial carbon
5) innegra in between carbon layers.
carolina Posted - 10/21/2018 : 20:40:38
[edit monday 22nd night time: sprayed on 6 coats mavcoat with tiny gun, wiped down with paper towel between coats every 15 mins then covered again as in pic below]. Next clear gelcoat.
[2nd edit, it’s night time... The mavcoat is now covered with mix of duratec hi-gloss additive and clear gelcoat & its dry to touch for hours but i will let fully cure before layup of cabon.]

Mavcoatmoldrelease.com taught me this & allert @ velomobiel.nl:
1)cover after cleaning lower tool with alcohol.
2)cover after spraying 6 coats of mavcoat release.
3)cover after spraying clear gelcoat over Mavcoat release.
4)after you pull your carbon part out of mold/tool, cover again & be ready to make another part which is the beauty of mavcoat release.
5)painter, very happy,, he or she sands clear gelcoat and then do their thing.

Brevity & misspellings rampant


carolina Posted - 10/15/2018 : 13:34:18
[update] just prepping the big lower mold here on friday.

Now lower mold is complete and ready to prep and layup a unibody.

Drilled, top mount curing in flox/epoxy. Couple blemishes covered in micro.

Here is pic of upper top:


carolina Posted - 10/14/2018 : 15:00:28
Mold made today, sunday afternoon. Took few hours today and couple hours last night.
1)last night, orange polyester tooling gelcoat (1hour between 4 coats).
2)then two layers of 3/4 oz. glass mat using polyester.
3)today 6 layers of carbon 11oz. twill using epoxy. (Always e over p).
4)orange peel-ply.
5) cure tomorrow evening, trim it and smooth it Monday.
6) near a yard of carbon used.
7)near 47 days
8)had top here for year, was time to work on it.

BOUT 15 minutes this Monday morning to take apart, very happy with mold and mavcoat release chemicals: 3 small blemishes to fix. 1)orange mold, 2)grey plug.


carolina Posted - 10/09/2018 : 17:58:08

Finally sprayed a coat, now some find sanding. First week or so of prep l brush on primer/some gets sanded off with the fine glaze filler. Ive am much better with small top cup spary guns from harbor freight, & cleaning gun is easy nowdays with the sprays they have at autobody warehouse. Or carb cleaner does good to and cheaper.

Been on this plug project 42 days.


carolina Posted - 10/06/2018 : 11:58:27
Working on rain gutter under intersection. Orange plug is almost complete, takes only hours to layup the mold on it if you use epoxy tooling gel coat, day or so more if useing polyester tooling gel coat.

You can see cut intersection of rear cowling and front top.

Couple days shaping rain gutter with bondo.


carolina Posted - 10/03/2018 : 09:40:11
Grey the orange evercoat for some color wet-sanding on this plug.

Front of my R&D machine ive used over 3 years, outback is a quattrovelo rear-end. Love a pinion 18 speed german transmission.


carolina Posted - 09/28/2018 : 12:15:26

Still looks the same but much work: plugs (master) takes forever but the mold (tool) goes quick.

Nice view: and pedal clearance.


carolina Posted - 09/23/2018 : 11:51:01
Plugs some call the master: i hope more people start making plugs, molds, parts.


Building a floor out of poster board and hot glue to capture a floor of 1/2” to 3/4” bondo that will be sanded to shape. Building up bondo 3 hours.

Brevity & misspellings rampant.

Without cnc these are tools i use below with bondo, foam, balsa, lauan wood.

1) cleico plyers and cleico’s. (Aircraftspruce.com or The yard)
2) soft tape measures
3) shipwrights divider bought on ebay vintage
4) profile gage on ebay

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:)



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