Kz1000 Carbon Fiber Fuel Tank

Thanks for chimming in kzbobber. My mold release system is Rexco Formula Five mold release wax and Partal #10 PVA

Any issues I have had separating the mold from the plug has beens my own fault, and not the release system. Any other tips or tricks you might be able to share?

Once the second coat of tooling gelcoat, cured i inspected it closely for any signs of my previous alligatoring issues from the bottom mold. The good news is that there was no alligatoring on the tank. The bad news is there was a little bit on the edge of the flange here and there. It seems to have only shown up where the first gelcoat was thin. So, once the 2nd coat (brushed on) cured, I mixed up a small batch of resin with some West Systems 404 High Density filler. I spread this into the corners, around the edges of the mold and around the emblem studs to soften the radius and make it easier to lay the reinforcement. I should have done this in some spots on the bottom mold, but hey, you live and learn.

From the newest pic it looks like you are having some problems with lifting. Are you using a wax and grease remover and wiping down the tank before you are moving forward? also to help the mold release from the tank you can use air. lift back a corner of the mold and spray some air in between the tank and the mold, this will help separate the two.

kzbobber1 wrote:

From the newest pic it looks like you are having some problems with lifting. Are you using a wax and grease remover and wiping down the tank before you are moving forward? also to help the mold release from the tank you can use air. lift back a corner of the mold and spray some air in between the tank and the mold, this will help separate the two.

kzbobber, are you refering to the vertical lines in the side of the tank? If so, that's not lifting, those are brush streaks. I hit those with sandpaper to flatten them a bit before I placed my first layer of reinforcement. If you are refering to the alligatoring on a couple spots on the flange, that is due to solvent penatration of the second coat into the first where the first coat was thin

I had some concerns about the removal of my emblem studs. The only thing I did was spray them with PVA, and I kept wondering if I should have put a light coat of grease or something on them. So once I had the mold just about complete, I was ancy to try and unscrew them.

I'm happy to report that with some effort (visegrips) I was able to break the surface adhesion of the resin/PVA/steel sandwich and unscrew the stud. After I cleaned it off and cleaned out the hole, I'm happy to say it threaded right back in. So far, things seem to be working out :silly:

After adding a few more pieces of cloth on the flanges and reinforcing the emblem stud holes, I deemed the right mold completed and stripped the parting board. After removing the clay, peeling off the PVA and removing my protective masking tape layer on the left side, it looks like this

After I clean things up a little more, I will glue a flange along the seam like I did on the rigth side. Then I'll PVA it and start the layup :woohoo: Since the left side is just a mirror of the right, I won't post any pics of this layup unless they are requested. I know more than a few people read this thread, but most are lurkers that don't ask questions :laugh:

I was looking at the brush strokes. it looked like it was lifting. it looks great man keep it up. looking ahead, I have a question. what are you going to do about the mold line that will be down the center of the tank?

Very intuitive question kzbobber. The parting line will be block sanded prior to paint and clearcoating.

oh, I guess I have not really read this whole thread. I thought you were making a carbon fiber tank. Meaning you would leave the carbon fiber exposed and just clear over it.

kzbobber1 wrote:

oh, I guess I have not really read this whole thread. I thought you were making a carbon fiber tank. Meaning you would leave the carbon fiber exposed and just clear over it.

I am. I would still need to sand the raw epoxy for mechanical adhesion of the clear. My plan is to paint it with a Z1 paint scheme, Leaving the raw carbon exposed for the base "color"

porchev914 wrote:

most are lurkers that don't ask questions :laugh:

HEY! :ohmy: I resemble that remark!!!

Cool thread.

porchev914 wrote:

After adding a few more pieces of cloth on the flanges and reinforcing the emblem stud holes, I deemed the right mold completed and stripped the parting board. After removing the clay, peeling off the PVA and removing my protective masking tape layer on the left side, it looks like this

After I clean things up a little more, I will glue a flange along the seam like I did on the rigth side. Then I'll PVA it and start the layup :woohoo: Since the left side is just a mirror of the right, I won't post any pics of this layup unless they are requested. I know more than a few people read this thread, but most are lurkers that don't ask questions :laugh:

Do you have any pics of the inside of this mold yet, or are you gona show them together when their done?