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Cosmetics and Lighting Modification Discussions External and Internal cosmetics modifications.

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Old 05-24-2013, 10:46 PM   #1
Aubrey64


 
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My Carbon Fiber Project

So after weeks of gathering supplies and parts and doing a ton of research, school is out and so I am finally ready to start my carbon fiber project of wrapping interior parts in real carbon fiber. I will post my steps and progress on this thread as I go, this will probably take a while as I plan on doing a lot of parts. Based on what others have told me I am fully prepared to screw up my first few tries but hopefully in the end it will all work out!
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Old 05-24-2013, 10:47 PM   #2
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Here is a picture of most of my parts/supplies:
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Here is what I have here:
- Real Carbon Fiber Cloth
- Resin
- Hardener
- Mixing Cups
- Kitchen Scale
- Stirring Utensils
- Black Spray Paint
- Heat Gun
- Dremel With Various Routing Bits
- Sharp Knives
- Gloves
- Sand Paper
- File


I think I am gonna start out with the driver side dash trim and the A/C bezel and then go from there
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Old 05-24-2013, 10:47 PM   #3
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I am setting up a work area in my garage tomorrow, and am gonna get started then. So I'll post some more pictures soon
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Old 05-24-2013, 10:49 PM   #4
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good luck!
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Old 05-25-2013, 12:01 AM   #5
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Looking forward to seeing how this goes! Good luck.
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Old 05-25-2013, 09:39 AM   #6
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can't wait to see how this goes. I want to do this myself.
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Old 05-27-2013, 12:16 AM   #7
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Day 1:

So far so good (I hope!) So today, I set up my work station in my garage, nothing special
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Now for what I have done so far. I decided to start out with small and flat parts, so I went with the center A/C Vent and the drivers side dash trim. I know it isn't a lot, but I thought it would be good practice.
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first, I sanded them with 100 grit sand paper.
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Next, I sprayed them with black spray paint. I did a couple of thin coats, nothing too much, but this was just so that if the carbon fiber was to separate, you wouldn't see the silver.
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Now that the parts are prepped, I then cut out the carbon fiber to the appropriate size.
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I am gonna start the wrapping in the morning, so this is all I have for today. But more will come tomorrow
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Old 05-27-2013, 12:17 AM   #8
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looking good.
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Old 05-27-2013, 02:06 AM   #9
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Great job so far. Keep taking your time and I'm sure everything will come out just like you plan. Looking forward to the end results.
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Old 05-27-2013, 02:23 AM   #10
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did you tape the end of the carbon fiber to prevent them from fraying (sp?)
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Old 05-27-2013, 02:23 AM   #11
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Good luck with them. The better the weather out, the better they seem to dry.
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Old 05-27-2013, 11:53 AM   #12
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Quote:
Originally Posted by rberns View Post
did you tape the end of the carbon fiber to prevent them from fraying (sp?)
Yes. Also helps keep the weave straight.
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Old 05-27-2013, 12:48 PM   #13
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Nice job so far thanks for posting
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Old 05-27-2013, 05:42 PM   #14
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Thanks guys for the comments and input, and if anyone has any suggestions on things I can improve, please let me know!


Day 2

Today I started actually wrapping the two pieces, the A/C vent came out pretty good I think (so far) but I am not sure about the dash trim, I may end up having to redo that piece, but I will wait and see. Here is what I have so far

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What I did was mix the Resin/Hardener to a 2:1 Ratio, and then I applied the mixture to the parts, and then let it get tacky before applying the carbon fiber, and then I just worked the carbon fiber around the part.

I am gonna apply the first layer of the Resin/Hardener on top of the carbon fiber once it is stuck fully onto the parts, so more will come soon
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Old 05-28-2013, 12:49 AM   #15
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Day 2 Continued...

So I worked on this for a long time today, and got all the Resin/Hardener coats onto the parts. And after each coat I went over the parts with a heat gun to pop the air bubbles. I found that the air bubbles where almost unavoidable, but the heat gun pops them. Just put the heat gun 6" above the part and you will see the bubbles begin to pop.

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After each coat, I let it dry and get tacky before applying the next coat.

Here is the first coat
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2nd coat
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3rd coat
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4th coat
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I did the 5th coat just now, and am gonna let it sit over night, so i'll post pictures of that soon. After the 5th coat is done curing overnight, I am gonna start cleaning up the pieces...which I am dreading, because this carbon fiber is as hard as a rock

But all in all I am really pleased with how it has turned out so far. Sorry for the crappy pictures, they are iphone photos and my garage is pretty dim. but more to come soon
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Old 05-28-2013, 12:55 AM   #16
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It cuts best when you use carbide and high rpm. The hardest part is yet to come for you.
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Old 05-28-2013, 12:57 AM   #17
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Quote:
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It cuts best when you use carbide and high rpm. The hardest part is yet to come for you.
Yeah I figured that the cutting would be the hardest...I am seriously dreading it! I got a dremel and a few different routing bits as well as a file to clean up some edges, so I am hoping that these things will do the job fine. If anyone has suggestions on how I should go about cleaning up the pieces, please let me know!
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Old 05-28-2013, 02:49 AM   #18
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Put tape on the good side so the gelcoat is less likely to splinter.

Whittle away at it. Like you said you can file the corners and such, sand on the edges, etc. A band saw would be great for most of the rough cutting. That stuff is hell on Dremel bits, watch the heat.

It's harder to cut than aluminum, but fragile as balsa wood...go figure?
Don't breathe the dust either.
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Old 05-28-2013, 10:38 AM   #19
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Did u buy a kit?
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Old 05-28-2013, 12:34 PM   #20
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Quote:
Originally Posted by two_wheel_mayhem View Post
Put tape on the good side so the gelcoat is less likely to splinter.

Whittle away at it. Like you said you can file the corners and such, sand on the edges, etc. A band saw would be great for most of the rough cutting. That stuff is hell on Dremel bits, watch the heat.

It's harder to cut than aluminum, but fragile as balsa wood...go figure?
Don't breathe the dust either.
Thanks for the info! It will help a lot

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Did u buy a kit?
Yeah, I bought a kit off eBay. It came with the hardner, resin, fabric, 2 paint brushes, gloves and a mixing cup. But the mixing cup and brushes where pretty much usesless
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Old 05-28-2013, 02:33 PM   #21
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would you happen to have the link? i want to try this out
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Old 05-28-2013, 11:53 PM   #22
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Looking good, may I suggest that next time you use a resin dye instead of paint, that will make for a stronger bond with you're piece, otherwise you're bond is only as strong as you're paint.
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Old 05-28-2013, 11:58 PM   #23
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would you happen to have the link? i want to try this out
Yeah, here is the link

http://www.ebay.com/itm/390508395879...84.m1439.l2649

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Looking good, may I suggest that next time you use a resin dye instead of paint, that will make for a stronger bond with you're piece, otherwise you're bond is only as strong as you're paint.
I will keep that in mind! I did put a layer of resin/hardener on before I applied the CF but after I painted it, which helped with the bond. I didn't even know black resin existed until after I had boughten my kit, so that is why I went with the spray paint route
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Old 05-29-2013, 12:02 AM   #24
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Yes, but the resin you applied first is bonded to the paint, and if the paint peals off......

I have a bottle of the dye, all you need is a few drops, let me know if you need some and I'll send you some for you're next pieces.
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Old 05-29-2013, 12:03 AM   #25
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Day 3:

So the 5th layer dried today, and here it is:
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It is a little bit uneven in spots, but I am planning on sanding it before adding the clear coat. So I am hoping the sanding will take care of the uneven spots. All in all, I am really happy with how it came out out so far! the next step is taking away the excess carbon fiber, so I am gonna start working on that tomorrow and I'll post pictures when I am finished
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