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

USA
596 Posts

Posted - 07/16/2016 :  15:11:22  Show Profile  Visit carolina's Homepage  Reply with Quote
Oh! l know layup schedule. You set around and think of it, great brain exercise. And l know people in the bizz who help me.

Frame of metal is a dirty word/literally. (my family started machine and welding company 35 years ago). I have welders here too but its very dirty. Shop is so clean without any welding. Thats why l love carbon fiber unibodies. I dont even paint (l roll on 2K primer & wet sand w/soap & hot water bucket). My velomobile want be painted, it will be wrapped. I could spray some accent stripes but that can be put on 52" printer @ wrap shop. Frans (pterovelo) suggested l wrap, l agree. No mess or overspray & quick and clean. Pick up velo finished same day.

IMO, Nowadays l like to use the word unibody for a carbon unit. Monocoque/or monocoupe as they say in usa is more related to older method of airplane building with a bucket of rivets and many pieces of aluminum that use each other for strength.

A modern cf lower shell mold (DF image) makes a one piece unibody as in pic below: Also ,, Earle Macpherson, chief engineer at chevrolet in 1945 design the macpherson strut that goes in this unibody front wheel wells. Thank you Earle.

[/URL]

My upper mold below is not needed till october or so:
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velosRus.com

Edited by - carolina on 11/24/2017 16:11:49
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carolina
recumbent guru

USA
596 Posts

Posted - 07/18/2016 :  13:04:54  Show Profile  Visit carolina's Homepage  Reply with Quote
nervous again, gotta teach myself how to spray duratec outside, bought some 707-202 gray. I have a plug l want to spray and buff to a higher gloss.

Gallon is 83$ to the door. Says shelf life is the normal 6 months. It will be gone before that.
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velosRus.com

Edited by - carolina on 11/24/2017 16:54:12
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carolina
recumbent guru

USA
596 Posts

Posted - 07/20/2016 :  09:09:46  Show Profile  Visit carolina's Homepage  Reply with Quote
Another realm of gearhead: I have departed to 4 speed up front on shop truck and and roadie cassette outback with help of another members educational time spent at my shop. When l get my cf/innegra unibody complete all this hardware will get moved over to unibody

google photo: my shop trike mule is heavy:

Mountain Tamer: below, call him!

[/URL]

Shop pac-mule (shop truck) below: been riding bout 10 months.

[/URL]

_________________________


velosRus.com

Edited by - carolina on 10/24/2016 16:51:41
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carolina
recumbent guru

USA
596 Posts

Posted - 07/23/2016 :  07:08:28  Show Profile  Visit carolina's Homepage  Reply with Quote
rear wheel well (wheel box)!

http://youtu.be/mF3oHfkN5uo

velosRus.com
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warren
human power expert

USA
6119 Posts

Posted - 07/23/2016 :  18:58:02  Show Profile  Visit warren's Homepage  Reply with Quote
Looks good. Keep up the good work.
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carolina
recumbent guru

USA
596 Posts

Posted - 07/26/2016 :  06:56:43  Show Profile  Visit carolina's Homepage  Reply with Quote
Popped out plug this morning:
1) for single swingarm set-up
2)rear wheel box
3) this is plug, will pull a 2 piece mold from it in couple weeks/not needed rite now.
4) hard part over with
5) Worked on this plug for months ever so often/on the side.
6) Turned out great.
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velosRus.com

Edited by - carolina on 08/27/2016 10:43:48
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carolina
recumbent guru

USA
596 Posts

Posted - 07/28/2016 :  18:17:53  Show Profile  Visit carolina's Homepage  Reply with Quote
Ha! real happy with duratec: l sprayed the rear wheel well plug today with it. Will help in the future. Sands like a dream after 2 hours. When finished, you can buff with the 2 compounds for a gloss. Should make a good 2 piece mold. l will look like amature instead of novice. Oh yea, iam pretty good cleaning gun.

[/URL]

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velosRus.com

Edited by - carolina on 08/05/2016 17:34:36
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carolina
recumbent guru

USA
596 Posts

Posted - 08/12/2016 :  18:16:28  Show Profile  Visit carolina's Homepage  Reply with Quote
love the duratec,, just sprayed rear bulkhead today. Now wet-sanding/sands like a dream. Then buff with 2 kinds of compound. Duratec polishes to 80% gloss. Check it out on YouTube.
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velosRus.com

Edited by - carolina on 09/03/2016 16:55:17
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Tom Schneider
recumbent enthusiast

112 Posts

Posted - 08/12/2016 :  19:04:54  Show Profile  Reply with Quote
Looking good.

Edited by - Tom Schneider on 08/12/2016 19:30:35
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carolina
recumbent guru

USA
596 Posts

Posted - 08/23/2016 :  20:30:40  Show Profile  Visit carolina's Homepage  Reply with Quote
Now working on rain gutter perimeter around the lower shell mold (nose area finished this week):

You must have cleicos:

[/URL]

I make these great plugs (carbon is layed over plug, then plug put in storage) with foam, bondo, blk vinyl floor tile heated to shape with heat gun & it holds shape great.
________________

velosRus.com

Edited by - carolina on 11/24/2017 16:15:01
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ncaudio
recumbent enthusiast

202 Posts

Posted - 08/31/2016 :  06:52:08  Show Profile  Reply with Quote
Coming along, looks good
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carolina
recumbent guru

USA
596 Posts

Posted - 09/10/2016 :  18:05:50  Show Profile  Visit carolina's Homepage  Reply with Quote
finished mold for belly inspection door: Black tooling gelcoat, soric, 2 kinds of carbon twill, peelply.

velosRus.com

Edited by - carolina on 09/27/2016 12:06:14
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carolina
recumbent guru

USA
596 Posts

Posted - 09/12/2016 :  18:51:47  Show Profile  Visit carolina's Homepage  Reply with Quote
buffing mold now for few days before applying chemicals for release of uni-body. 3 chemicals/three coats of each. Still polishing and polishing, then chemical release agents/14-September/2016/3:00est-USA

velosRus.com

Edited by - carolina on 09/14/2016 12:01:26
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carolina
recumbent guru

USA
596 Posts

Posted - 09/27/2016 :  12:05:43  Show Profile  Visit carolina's Homepage  Reply with Quote
Waw stuff came in:

[/URL]

velosRus.com
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carolina
recumbent guru

USA
596 Posts

Posted - 10/09/2016 :  16:31:49  Show Profile  Visit carolina's Homepage  Reply with Quote
Hot dang, 3 years to finish shop, molds, research, etc..
LAYUP ON ONE SIDE FINISHED: started other side, floor and bulkhead .

Love this innegra: installed in all flat & 1/2 round areas. Sandwich'ed between carbon fiber.

******WAITING ON MORE EZPOXY TO COME IN******************

[/URL]
____________________

velosRus.com

Edited by - carolina on 11/24/2017 16:16:36
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carolina
recumbent guru

USA
596 Posts

Posted - 10/19/2016 :  20:24:55  Show Profile  Visit carolina's Homepage  Reply with Quote
Fun layup tonight, finished 11:16/4 hours or so!

[/URL]

This one: innegra, cf twill, cf uni, biaxial.
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velosRus.com
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warren
human power expert

USA
6119 Posts

Posted - 10/20/2016 :  06:03:35  Show Profile  Visit warren's Homepage  Reply with Quote
No Vacuum Bagging?
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carolina
recumbent guru

USA
596 Posts

Posted - 10/20/2016 :  06:19:48  Show Profile  Visit carolina's Homepage  Reply with Quote
velos are not,,, quest, df, evo, waw, etc.. Boy!, your just a lost child,, iam gonna haf to edujamacte ya/:)

velosRus.com

Edited by - carolina on 10/20/2016 06:21:14
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warren
human power expert

USA
6119 Posts

Posted - 10/25/2016 :  09:03:59  Show Profile  Visit warren's Homepage  Reply with Quote
Velos are not vacuum bagged? Certainly easier to build without bagging and I would probably do the same, but I'm surprised that the production build guys don't vacuum bag to add strength and lightness.

Edited by - warren on 10/25/2016 12:00:23
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Speedbiker
human power expert

USA
3761 Posts

Posted - 10/25/2016 :  09:09:07  Show Profile  Reply with Quote
Daniel Fenn's personal velo is under 30 pounds. Pretty sure it was bagged. Hannon's SL sure looks like it was bagged.
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carolina
recumbent guru

USA
596 Posts

Posted - 10/25/2016 :  15:59:35  Show Profile  Visit carolina's Homepage  Reply with Quote
quote:
Originally posted by warren

Velos are not vacuum bagged? Certainly easier to build without bagging and I would probably do the same, but I'm surprised that the production build guys don't vacuum bag to add strength and lightness.



Just look down in one and stare at em a lil while. Ive had the quest and df's here at shop, l talk to Netherlands 2 to 5 times a month. How do u think l built this?,,, with their help. Is the answer. Guess the reason they dont use bagging is time and money savings and they have a great layup system with 5 females in romania.

velosRus.com

Edited by - carolina on 10/25/2016 17:49:12
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warren
human power expert

USA
6119 Posts

Posted - 10/25/2016 :  16:32:46  Show Profile  Visit warren's Homepage  Reply with Quote
You are making good progress!
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carolina
recumbent guru

USA
596 Posts

Posted - 10/25/2016 :  17:00:29  Show Profile  Visit carolina's Homepage  Reply with Quote
Glad to get this finished, not skeeeered to install hardwares for doctor. Cause same hardwares l installed in my trike. I will ride a lil and start on canopy frame plug.

canopy frame plug: [edit-took 10 days]
1) blk tooling get coat, cf, duratec.
2) will put 3 coats of mclube 818 around perimeter of rain gutter, then tooling gel, then carbon cloth layers, & crossmember support in middle.
3)Then the plug will make a good mold. Pull the part (canopy frame). Then fit test fg canopy.

I have couple ideas for forward hinging canopy. 1 from quattrovelo and 1 from pic below and mix the two ideas: Something not here yet.

What saves me is innegra:

http://youtu.be/0N-LiWRA7RQ
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Update thanksgiving 2017, tilt over canopy:

[/URL]
__________________

velosRus.com

Edited by - carolina on 11/24/2017 16:04:35
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carolina
recumbent guru

USA
596 Posts

Posted - 10/28/2016 :  06:23:31  Show Profile  Visit carolina's Homepage  Reply with Quote
The velomobile unibody is cured and ready to take out of mold. THIS IS A THREE PART MOLD WITH THE REAR ROLL OVER. So I decided to make a new rear rollover mold with real stuff like epoxy tooling gel coat. Before l take unibody out l will complete this small easy third part mold. Should be finished sunday evening and will take every apart monday morning.

Even though the first rollover mold worked it was made back when l knew less and it would be less durable. But with epoxy tooling gel and carbon over that l will have a lasting mold/tool as the pros call em.

The back of this rollover holds the rear cowling. The front 2/3rds of it has the rain gutter built in and is a seat for canopy behind seat.
________________________

velosRus.com

Edited by - carolina on 11/24/2017 16:01:34
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carolina
recumbent guru

USA
596 Posts

Posted - 10/31/2016 :  17:03:32  Show Profile  Visit carolina's Homepage  Reply with Quote
New epoxy tooling gelcoat mold w/soric and cf. The original rollover mold is in the gar' bage now. It cost me some days but well worth it.

[/URL]

brevity&misspelling rampant
__________________

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Edited by - carolina on 12/01/2016 20:24:33
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