Kz1000 Carbon Fiber Fuel Tank

Thanks Tyler I started to pull the mold this morning, but the flange still felt awfully thin. Unfortunately, I had picked up more 4oz fiberglass cloth, but I didn't get any of the heavier 6oz stuff because I thought I had some. Well, I didn't, so I made the mold just using the 4oz and some scraps of 6oz I had laying around. Turns out I didn't get nearly enough thickness to make a rigid mold, so I scuffed up the surface with a sanding disk and cut up some chopped strand mat I had and some more 4oz cloth.

TIP: Do not use chopped strand mat when using epoxy resin. Chopped strand mat is rather stiff because the glass fibers are held together with a styrene based glue. Only the styrene that is in poyester resin can break this down and alow the fibers to move and conform to curves. It will wet out with the epoxy resin, but it will not conform to any radius and stay put.

So, I went another round of glassing the mold, using the CSM for the flat flange areas and the cloth for the flange/part transition and over the parts hump. It looks wierd, like a strange alien or robot face...anyway, I'll set it out in the sun and hopefully demold it in a few hours

The sun wasn't out in force today, so I put my new mold in the oven at 200 degrees to help it cure a little faster Another benifit of the oven treatment was a good softening of the clay, making release of the mold from the glass plate super easy. I dug out the clay and pulled up the PVA and presto, I had a new mold. A couple of love taps with a punch and a hammer knocked the stock mounts out of the mold (They didn't want to come out so easy. This is the first time I have ever made a mold of a metal part).

This mold turned out pretty darn good I'd say! I just need to have enough of the right sizes of cloth on hand before I start another mold

hehe,it looks like a cross eyed baboon!

keep us posted,

leon

It kinda does, doesn't it Leon? Well, I decided last night to go ahead and try to pull some parts out of my new mold. After the last coat of mold release wax, I noticed a small crack in the epoxy in one of the side mounts. Further investigation revealed a small air pocket Not to worry though, I needed some practice patching molds since my tail mold needed some work as well. I mixed up some fast resin with some graphite and filled in the void. I did the same to a LARGE void in the tail mold. That particular bubble wasn't in the part itself, but if left it would have locked the new part it once cured :blink: I checked the molds this morning and it looked like the patches did the trick, so I'll try a layup this evening....maybe not, it is valentines day :kiss: At the very least I'll get more of the tail mold patched up. I'm gonna be a parts makin' soon!

TIP: Additives affect the cure time of resin. In my patches I used fast hardener which has a 10 minute pot life. With the addition of 30% graphite, the pot life goes up to 30+ minutes, and cure time increases signifigantly as well.

good tip on the "pot" life.

Its important to note that different admixtures may have different effects on pot life, as well as the quantity of admixture used. Test mixes should be performed so that you KNOW the characteristics of your resin matrix. If you assume or go off of an unverified claim, it WILL bite you in the ass. That's how I wasted $100 in materials experimenting with an unfamiliar resin on my initial tank top piece :S

I didn't finish getting the tail mold patched up. One more batch of resin for patching though, and I can give the mold a shot. I did get a layup on the tank mounts.

I worked the piss out of the corners and edges with the tongue depressor, so I have my fingers crossed that the mounts will come out ok.

And we have some carbon tank mounts

I have them pictured with the stock steel mounts. I wish I had a belt or disk sander, it would make trimming straight edges MUCH easier and faster than a carbide bit in a drill press.

www.harborfreight.com/air-belt-sander-97055.html

i bet you could find several uses for this one. adam.

your parts do look good,

leon

I'm getting closer to your tail Leon. If anything, I'm working toward a better mold

i got faith in ya man!
after everything we have watched you do all i want is you to have more time and material money :laugh: .

leon

You ever think about making a carbon fiber airbox?

www.cyclemadness.com/cmforum/index.php?topic=680.0


My brother has been playing around with making custom CF kayak paddles, I'm how far a little sweet talk would get me?