www.recumbents.com - Carbon mold/tool for lower&upper enclosed velo
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carolina
recumbent guru

USA
516 Posts

Posted - 05/15/2014 :  12:24:23  Show Profile  Visit carolina's Homepage  Reply with Quote
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:

[URL=http://s1244.photobucket.com/user/velo211/media/7F21C331-607D-4C97-8F0C-AB7FEBD23FF5_zpsfn3rsgqe.jpg.html][/URL]
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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.

[URL=http://s1244.photobucket.com/user/velo211/media/6ED633E7-7B39-4FE1-AFB8-78D5CF3EABBA_zps67d1xho5.png.html][/URL]

velosRus.com
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brevity&misspelling rampant

Edited by - carolina on 07/18/2016 19:28:39

warren
human power expert

USA
6050 Posts

Posted - 08/09/2014 :  09:28:52  Show Profile  Visit warren's Homepage  Reply with Quote
Good progress Mike. This will be for a trike, right? Wheels on the inside of the fairing?
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carolina
recumbent guru

USA
516 Posts

Posted - 08/09/2014 :  18:04:49  Show Profile  Visit carolina's Homepage  Reply with Quote
warren, This will not be shell for a trike, this is full velomobile. My velomobile is a frameless unibody.

Square cf tubes l make will be used on 2 wheel low racer .

l make my own carbon square tubes (rewarding project l took on to learn) and carbon plates sold on ebay under toys and hobbiest section. Two part bladder mold for the square cf tubes:

https://youtu.be/P25gYPUqtB8

[URL=http://s1244.photobucket.com/user/velo211/media/69CE7BE3-2C8E-4524-9481-A3A82AB58C7E_zpseuojmxh0.jpg.html][/URL]

BELOW IS STOCK VELO FRONT MCPHERSION SUSPENSION / COME WITH STURMEY ARCHER BRAKE DRUMS:


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The rear will be like below with close-out bulkhead (did order new rear suspension) @ rear like WAW velo: Rear Cowling not in photo.

[URL=http://s1244.photobucket.com/user/velo211/media/A5EB329F-3443-44C3-9783-516BDFC47D98_zpsxlwuiihr.jpg.html][/URL]

_________________
velosRus.com

Edited by - carolina on 07/18/2016 19:25:27
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warren
human power expert

USA
6050 Posts

Posted - 08/11/2014 :  07:43:50  Show Profile  Visit warren's Homepage  Reply with Quote
Wow, there are lots of interesting bits on that drum brake hub. Looks like you have been busy!
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mhelander
recumbent enthusiast

Finland
383 Posts

Posted - 08/12/2014 :  02:33:18  Show Profile  Reply with Quote
quote:
Originally posted by warren

Wow, there are lots of interesting bits on that drum brake hub. Looks like you have been busy!



Very interesting... did you use factory made suspended linkage assembly or fabricated it yourself ? If latter, what kind of bearings if I may ask ?

Cheers,
-Mika

Diy bents: Full-suspended off-roader @ 2012, Vendetta clone @ 2012
Commerials: MetaPhysic 700c @ 2011, M5 CrMo Lowracer @ 2010
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carolina
recumbent guru

USA
516 Posts

Posted - 08/16/2014 :  09:05:48  Show Profile  Visit carolina's Homepage  Reply with Quote

Great top wheel well gusset. Super strong, no flex.


Bottom bracket:

Edited by - carolina on 07/05/2016 18:13:45
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rickmantoo
recumbent enthusiast

USA
274 Posts

Posted - 08/25/2014 :  12:21:36  Show Profile  Reply with Quote
Carolina
Great job on building the parts! I really like the way you are molding them. That is one advantage of using female molds.
So I see in your pictures that you have a set of ICE front suspension hubs that you were/are planning on using, but when you show the front wheel wells it looks like you are setting them up to use McPherson Strut style front suspension. So are you just leaving your options open at this time?
Keep posting pictures it is great to watch your progress.

Rick W
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carolina
recumbent guru

USA
516 Posts

Posted - 09/08/2014 :  05:12:39  Show Profile  Visit carolina's Homepage  Reply with Quote
Making my own carbon plates: Soric honeycomb and carbon fiber twill 12K.

Lay-up is between two granite plates (3/16 or 1/8") : I make 6"x8" plates, They are great & straight.

Edited by - carolina on 07/05/2016 18:25:02
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carolina
recumbent guru

USA
516 Posts

Posted - 12/28/2014 :  10:20:04  Show Profile  Visit carolina's Homepage  Reply with Quote
Dad gave his harbor freight mill he bought at estate sale.

Edited by - carolina on 07/05/2016 18:17:20
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warren
human power expert

USA
6050 Posts

Posted - 01/18/2015 :  15:49:43  Show Profile  Visit warren's Homepage  Reply with Quote
Lots of gelcoat and carbon fiber goodness!
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warren
human power expert

USA
6050 Posts

Posted - 01/20/2015 :  06:48:00  Show Profile  Visit warren's Homepage  Reply with Quote
Hey Mike, I recommend polycarbonate or even PETG over acrylic. Acrylic tends to break into sharp shards when broken.
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carolina
recumbent guru

USA
516 Posts

Posted - 03/07/2015 :  16:15:37  Show Profile  Visit carolina's Homepage  Reply with Quote
Front bridge @ wheel wells will look like this but flat floor & plastic tubes a chain tunnel below.

[URL=http://s1113.photobucket.com/user/putt2012/media/4376CA6E-CE1A-4F29-8056-BED3F2DAD4FB_zpsl6ezz2vu.jpg.html][/URL]
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AviationMetalSmith
recumbent enthusiast

USA
251 Posts

Posted - 03/22/2015 :  09:43:43  Show Profile  Visit AviationMetalSmith's Homepage  Reply with Quote
You must have spent at least 750 hours working on it?
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warren
human power expert

USA
6050 Posts

Posted - 04/14/2015 :  05:57:52  Show Profile  Visit warren's Homepage  Reply with Quote
Happy Anniversary! I know you have been thinking about this project for well over a year, and it shows.
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carolina
recumbent guru

USA
516 Posts

Posted - 04/14/2015 :  16:59:48  Show Profile  Visit carolina's Homepage  Reply with Quote
Yea, warren thanks! It's a year of working and more to go. I have wheel wells now, bottom brackett boom towers figured out. I have wheels from netherlands, rohloff from cyclemonkey. Making 5 molds over next 30 days.
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carolina
recumbent guru

USA
516 Posts

Posted - 04/17/2015 :  17:21:03  Show Profile  Visit carolina's Homepage  Reply with Quote
Bought a rear cowling (wind fairing) from europe. l will make a plug with it and then pull a tool from it. It will speed up the rear. Pressure recovery unit, lets call it! So easy to change rear tire.

Edited by - carolina on 07/05/2016 18:58:23
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carolina
recumbent guru

USA
516 Posts

Posted - 12/30/2015 :  19:10:04  Show Profile  Visit carolina's Homepage  Reply with Quote
I did build a velo trike with all velomobile parts, love it, ride it often (8 months). Blew the catrike 700 to lil' pieces. Sold the catrike. This is my basic shop learner vehicle. In Europe these are called "mules". A mule was used to design the 4 wheel velo in the Netherlands. So l built myself a three wheel mule.

SHOP TRUCK BELOW: GREAT FOR GROCERIES

[URL=http://s1244.photobucket.com/user/velo211/media/90D7C0F7-34C6-4939-A21A-CFA823D34983_zpskj9ct7oq.jpg.html][/URL]

[URL=http://s1244.photobucket.com/user/velo211/media/DBE6C08B-F4A2-4E09-A575-6F967AA0EF0B_zpsk9j3kr5q.jpg.html][/URL]

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velosrus.com

Edited by - carolina on 07/05/2016 19:12:16
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carolina
recumbent guru

USA
516 Posts

Posted - 03/08/2016 :  08:18:29  Show Profile  Visit carolina's Homepage  Reply with Quote
Chain canal, heel wells started, Rear bulkhead installed, (fill, shape, prime, sand, wax, buff.

[URL=http://s1244.photobucket.com/user/velo211/media/2D9AC0BC-4138-401B-A4FF-29834D62F215_zpsppzvbgbu.jpg.html][/URL]

Rear bulkhead @ floor and chain canal.

[URL=http://s1244.photobucket.com/user/velo211/media/661A58ED-38F7-4F5D-BDB8-7A95149FAB05_zpsjwmrkebk.jpg.html][/URL]


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velosRus.com

Edited by - carolina on 07/06/2016 08:45:34
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carolina
recumbent guru

USA
516 Posts

Posted - 07/05/2016 :  18:02:27  Show Profile  Visit carolina's Homepage  Reply with Quote
Tuesday 5 july 2016: rear bulkhead in the moldand 2 part rear wheel well mold complete and curing couple days.

[URL=http://s1244.photobucket.com/user/velo211/media/D08673D9-51BB-48AD-AB48-ECE5018AFA41_zpshyedkrab.jpg.html][/URL]

bridge mold complete and made a carbon bridge with innegra sandwich'ed.

[URL=http://s1244.photobucket.com/user/velo211/media/6E74C295-C124-40C8-A7AC-19635E1BF794_zps0a2sghyk.jpg.html][/URL]

mold below: loaded with part curing

[URL=http://s1244.photobucket.com/user/velo211/media/02981147-124F-424D-AC52-8E8C3A3CD189_zpsv6p7fqo5.jpg.html][/URL]

l sold a shell to family doctor, he wants open top velo unibody/ not enclosed.
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velosRus.com





velosRus.com

Edited by - carolina on 07/16/2016 06:34:34
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carolina
recumbent guru

USA
516 Posts

Posted - 07/05/2016 :  19:10:20  Show Profile  Visit carolina's Homepage  Reply with Quote
if you have a shell you have a shell!! All the velomobile hardwares come to your from door as they come to my front door. I make all orders to Europe on my iphone for 2 years. Very simple, excellent service. velomobiel.nl, intercity bikes, katanga.eu

All modern parts come from Europe nowdays for a velo. (rohloff, pinion, alligt parts, etc..)

[URL=http://s1244.photobucket.com/user/velo211/media/4A5B5D99-F11C-44CD-BAAC-86D6BB261FFC_zpsuro8ttx2.png.html][/URL]

_________________________
velosRus.com

velosRus.com

Edited by - carolina on 07/16/2016 06:45:29
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carolina
recumbent guru

USA
516 Posts

Posted - 07/05/2016 :  19:16:37  Show Profile  Visit carolina's Homepage  Reply with Quote
My upper mold: not needed till fall.

[URL=http://s1244.photobucket.com/user/velo211/media/79C28ECA-87CA-4A6C-92A5-41573D4D0325_zpsw2qpncr4.jpg.html][/URL]

velosRus.com
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carolina
recumbent guru

USA
516 Posts

Posted - 07/06/2016 :  21:27:01  Show Profile  Visit carolina's Homepage  Reply with Quote
[URL=http://s1244.photobucket.com/user/velo211/media/2D9AC0BC-4138-401B-A4FF-29834D62F215_zpsppzvbgbu.jpg.html][/URL]

The rear wheel well mold will be cure tomorrow and i will take it out and clean up all the tape and stuff. Trim the mold outside and polish edges. Wash it and seal with frekote. Has a great chain canal that adds super strength to velomobile with innegra,twill, & biaxial carbon cloth layup. Honeycomb (soric) & innegra used certain places during layup. FRONT WHEEL WELLS ARE IN THE LOWER SHELL MOLD PERMANENTLY TO MAKE A STRONGER UNIBODY.

velosRus.com

Edited by - carolina on 07/16/2016 06:42:56
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carolina
recumbent guru

USA
516 Posts

Posted - 07/07/2016 :  17:37:20  Show Profile  Visit carolina's Homepage  Reply with Quote
A beautiful tool now here to make cf rear wheel wells strong as steel. Epoxi carbon soric tool (mold) to make great parts. Been bout 10 days on this project/ very rewarding too.

[URL=http://s1244.photobucket.com/user/velo211/media/6201E6FA-D77B-453E-BAC9-CE02C8FE87F0_zpstjg3mow8.jpg.html][/URL]

Home movie industry:

http://www.youtube.com/watch?v=4e9GU-FQU2Y
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velosRus.com

velosRus.com

Edited by - carolina on 07/12/2016 20:31:04
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carolina
recumbent guru

USA
516 Posts

Posted - 07/09/2016 :  14:40:51  Show Profile  Visit carolina's Homepage  Reply with Quote
Yes, another rear wheel well project: for single swingarm rear wheel well. One more step in this project. I made this to make a plug,, that i will duratec and polish to hi-gloss. Then pull a two piece mold from that. I will have 2 rear ww's that fit perfect with windshield adhesive. (as per quest instructions).

[URL=http://s1244.photobucket.com/user/velo211/media/443BB548-3FA7-4756-9957-B238F3128C3B_zpsswiq9rj1.jpg.html][/URL]

WAW rear chain wheel:

[URL=http://s1244.photobucket.com/user/velo211/media/BC62385E-695F-407B-AEA3-FBE220F8DC65_zpsttax9aso.jpg.html][/URL]

__________________

velosRus.com

Edited by - carolina on 07/16/2016 06:38:14
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carolina
recumbent guru

USA
516 Posts

Posted - 07/09/2016 :  17:14:52  Show Profile  Visit carolina's Homepage  Reply with Quote
Techniques for fast layup and straight cuts. I learned this in 93 when we built the Lancair 320. I use some vinyl floor tile, visqeen plastic. I sandwich'ed the carbon between visqeen that is wet. Then roller cut perfectly square and pick up with gloves and lay in place gentle. You can stipple with finger and brush. Sometimes l put on peel ply with finger holding it in place till wet.

This method makes a perfect square patch or bid over joggle that looks professional.

[URL=http://s1244.photobucket.com/user/velo211/media/4357E8F6-1D0A-4FAC-8AD0-5B90D6688A12_zps2b5dymlg.jpg.html][/URL]

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velosRus.com

Edited by - carolina on 07/09/2016 18:13:01
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carolina
recumbent guru

USA
516 Posts

Posted - 07/11/2016 :  19:56:17  Show Profile  Visit carolina's Homepage  Reply with Quote
After way to many hours on this ... rear roll-over w/Raingutter. Its curing now and l can maybe finish soon but the hard part is finally over. @$$ whoppin & feel like l lost.

[URL=http://s1244.photobucket.com/user/velo211/media/13EEB1D3-3E4D-4738-8A3D-EB5B499C026B_zpse85ndpv4.jpg.html][/URL]

velosRus.com

Edited by - carolina on 07/11/2016 19:57:24
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