trying to make carbon fiber intake tube?? 1

[yama450yfz]

I am trying to make a carbon fiber intake tube for an ATV. I have made a foam mold so far. I was told that foam should not react to the epoxy and that after I wrap the piece in carbon fiber. I should be able to use paint thinner to get the foam out of the middle. This will be my first time experimenting with composites. I have no knowledge on the subject and any help would be great. Thanks

 

[berkshire]

yama450yfz (Automotive)
This is true if you are using Styrofoam, if you are using polyurethane foam it will not dissolve with thinner.
B.E.

 

[yama450yfz]

Yes, I am using styrofoam. My next question is. Should I use a carbon fiber sleeve and just pull it over my tube?, Or should I just wrap the tube with carbon fiber sheets? I am also looking to have as smooth a surface possible on the inside and outside of the tube.

 

[MikeHalloran]

Wrap the styrofoam with Saran before applying the carbon, etc., and wrap Saran over the carbon and resin before cure.
The Saran will peel away from epoxy easily once the epoxy has cured.

Warning: There will be deadly sharp edges and/or needles where the Saran has not sealed tightly on itself, and a little epoxy and/or carbon seeped into the joint or a wrinkle. BE CAREFUL.

I have not tried the Glad Press'n Seal film, but since it adheres to itself, it deserves investigation.





Mike Halloran
Pembroke Pines, FL, USA

 

[berkshire]

If you have a knitted or braided sleeve this would be the easiest method. Slide it over your intake mold and pull on it to reduce the diameter to fit.
I second Mikes Saran wrap method. You can also heat shrink it a little with a hair dryer, ( Not too much or you will shrink your styrofoam.) to get it tight on your mold, three or four wraps should be enough.
B.E.

 

[yama450yfz]

How many sleeves would I need in order for it to be sturdy enough not to break? Is there any special technique to using a sleeve?

 

[berkshire]

I cannot answer that because I do not know what your loads are and how heavy the carbon fiber you are using is.
You may have to experiment to find out.
I would suggest making an inlet duct out of glass fiber first, to play with, then making a duct out of the more expensive carbon fiber when you have the bugs out.
B.E.

 

[yama450yfz]

Can you help me find a good place to purchase a 2" carbon fiber sleeve from? The only place I have been able to find will only sell the sleeves in 10 meter increments.

 

[Compositepro]

You can get braid by the yard here:

http://www.fibreglast.com/product/Braided_Carbon_Biaxial_Sleeve_02609_1/Braided_Sleeves

 

[yama450yfz]

Thank you all for your help.