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 Carbon mold/tool for lower&upper enclosed velo

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carolina Posted - 05/15/2014 : 12:24:23
How l started. My airplane molds (BD-5) l own are used for cf velomobile unibody. Ideas/conversations are welcome: march-7-2015 [This past MAY has been 2 years].

My molds favor this shape:

Rear cowling will look like this photo below, my velo at rear is 5" wider: plus i have a rear bulkhead like the WAW velomobile.

brevity&misspelling rampant
25   L A T E S T    R E P L I E S    (Newest First)
carolina Posted - 02/21/2020 : 11:29:17
Gates corporation. Denver Colorado. Gates carbon belts and gears for all bikes. Including Pinion gearbox痴, Rohloff痴 and more. 2/3/4 wheelers.

Stuff came 2/21/2020 friday. Gearbox drive experiments.


carolina Posted - 02/19/2020 : 14:14:50
Gates carbon belt and gears coming tomorrow for 4 wheeler experiment.

Been sanding and fitting rear cowling to top for 10 days.

2/21/2020 friday morning: just slow process of sanding top plug. Rear grey plug ready to pull mold, stuff will be here tuesday. Rear cowling and top plugs are around 40 pounds now. Will go to storage in lawn leaf bags after l pull molds. Sand an filll sand an filll sand an fill:)

Last years top: full canopy/sold


carolina Posted - 02/08/2020 : 18:51:46
update: its saturday night 8th feb 2020


carolina Posted - 02/06/2020 : 14:43:10
4 wheeler with great used rohloff from ebay.


carolina Posted - 02/03/2020 : 20:55:43
Notha experiment: schlumpf gone, putting rohloff in nose. Oh well, we will see this week. One short chain on the twin cog rohloff and longer 2nd chain going back to rear.


carolina Posted - 01/26/2020 : 15:55:58

1)Since i will ride with top on or off till completed I used the DF velo rear seat hardware to change out back and forth while body work on top plug goes forward. Cotton flox will cure til 6:30 then layers of carbon over these two pieces of wood that is the base mount.
2)this allowed me to remove the temporary crossmember behind seat l been using since beginning. Plus try out this new idea of seat resting on headrest from daniel Fenn. If i make a new top modified seat, l can cut this experiment off of the plug.
brevity & misspelling rampant:

carolina Posted - 01/23/2020 : 02:41:24

1)above photo is tab on both sides of milan gt seat.

2)Below pic: the seat rest in these floor mounted bracket saddles, L&R on floor,, u can see how easy it is to take seat in and out.

3)Below photo is another great idea: seat top leans on headrest getting rid of any other upper hardware.


carolina Posted - 01/23/2020 : 02:38:38
Slower shop after trigger finger operation 22/jan.,,, right ring finger. ibuprofin/hydrocodone.

carolina Posted - 01/20/2020 : 16:46:38
zoom in and you can see i cut manhole out today from the rest of the rear top and moved it forward 2&1/2 inches. I also reshaped hole where knee bumps will go into top.


carolina Posted - 01/19/2020 : 11:01:14
milling the plugs nowdays of thick fglass. it痴 much better.


carolina Posted - 01/19/2020 : 10:13:53
working on this a week. Now riding again. Twin sturmey archer drum brakes at rear now @ at all 4 wheels now.



carolina Posted - 01/07/2020 : 22:40:09
Took quattrovelo rear end out again to install left sturmey archer drum brake. Alot of work.

Now L&R drum brakes are complete, installing will take some more work. i love this setup for alot of reasons. The quattrovelo rearend is a great design. rides like a dream.

beautiful photo below:


carolina Posted - 01/06/2020 : 20:28:51
More milling tonight:
Machine last part for left side sturmey archer drum brake on rear of 4 wheeler. Like to have a harbor freight lil laithe.


carolina Posted - 01/05/2020 : 20:13:50

PINION GEARBOX:base mount in carbon.
worked last night up til now on this pinion 18 speed mount mold. Black custom fitted pinion plug u see got me here. The center part between two orange pieces l poured down in between two orange parts (cotton flox and poly resin) for the 3rd part of this mold. lt is tight & fits incredible. Never tried that before.

l have L & R trim fixtures after part comes out. All six holes of finished part are pre-drilled before relief from mold. Then trimmed and 6 aluminum rivnuts installed.

carolina Posted - 01/05/2020 : 17:39:47

2 piece mold for pinion gearbox mount.

carolina Posted - 01/05/2020 : 14:34:25
these from harborfreight are really usefull in shop big time: trim micro, bondo, wood,& more.


carolina Posted - 01/05/2020 : 14:08:14
harbor freight milling a two piece mold:

carolina Posted - 12/23/2019 : 11:44:24
PHOTOBUCKET is down right now but pics can come later.

I have finished pinion and rohloff middrives finally as a display. Either gearboxes go behind seat on floor low down in the wide chain valley for next year.

I am still using the hilgo floor shifter and 9 sp cassette in the 4 wheeler with F. Schlumpf mountain drive 2 sp crank up front.

carolina Posted - 12/06/2019 : 06:23:33
Nothing going on but slow bondo sanding every day. These are all plugs below to pull molds from:

Grey is the plug/master that the mold will be made from , ready for wet sanding soon:

The lower of this rear cowling is already a mold, the grey area will be 1 of 3 piece mold.

jan 5/ wet sanded, sprayed 3 more coats, now last wet sand and polish.

Also as said before: fiber glassed over toe clearance humps with 40 ounce fglass/2 layers. Honed out inside and put it on velomobiel for test ride/all good. Now iam adding bondo over fglass to sand and ready the two humps & whole part for grey epoxy primer.


carolina Posted - 11/30/2019 : 23:31:15
Mod弾d shop vac.

Channel 菟ushyhog
carolina Posted - 11/29/2019 : 20:42:41
Just different options. You値l haf to read all the post.

No delrin and not near any heat. They say not to use rear brakes that much just the other day. I installed sturmey archer, i love em and on all 4 wheels.

1) you saw the stock pics of quattrovelo with mid-drive ROHLOFF up above.
2) hilgo floor shifter is for 3 wheeler, but i had a trial with it. Pretty good!
3) the Pinion middrive with short gates belt is my project. A take-off on rohloff痴 middrive.
4) read about the quattrovelo with straight axle, can jump cogs over humps.
5) last year was 3 wheeler with bafang up front and rohloff at rear in waw linear supension.
6) oh, dont forget the schlumpf mountain drive up front now.
7) everyone wants something different.

Jeroen s Posted - 11/29/2019 : 09:38:35
OK i am losing track of all the gearing options going on here. A Pinion in front, a Hilgo middrive, a rohloff and then the cassette on the rear axle?

Next to the drumbrake i think i see a delrin spacer. Would that cope with a hot drum?

Greetings, Jeroen
carolina Posted - 11/28/2019 : 12:27:01
Amature build here:
1) a useable plug to test ride.
2) covered over all the foam/bondo work with fglass.
3) pedal clearance now close to wet sanding.
4) also rear cowling plug is getting ready to be sprayed with primer.

I sanded out inside of clearance humps with 3 different tools:
1) now l can ride and see if alls well on clearance.


carolina Posted - 11/23/2019 : 16:38:50
Still having fun with 1)hilgo floor shifter that belongs in 3 wheeler, but its pretty good in the 4 wheeler. This one is 9 sp 11/23. 2) schlumpf mountain drive up front.


carolina Posted - 11/20/2019 : 16:49:02
Quattrovelo differential.

11/23 cassette 9 sp/Schlumpf drive up front.


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