www.recumbents.com - Carbon mold/tool for lower&upper enclosed velo
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 Carbon mold/tool for lower&upper enclosed velo
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carolina
human power supergeek

USA
1059 Posts

Posted - 08/22/2018 :  13:42:08  Show Profile  Visit carolina's Homepage  Reply with Quote
Priming windows to install tonight with DOW u-428 windshield adhesive. If you don稚 use dow primer the plastic window can not hold over time with the dow adhesive. I scuff plastics perimeter and brush on primer.



Dow primer/ebay. If damaged windshield needs to come out, a wire will cut it out. I take stock caps off and find a tight top of something around the shop. That way the tube does not dry out. Figured that out the hard way.


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Edited by - carolina on 08/22/2018 13:45:46
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carolina
human power supergeek

USA
1059 Posts

Posted - 08/23/2018 :  05:14:03  Show Profile  Visit carolina's Homepage  Reply with Quote
4 long years people:

the silver reflector DOT tape will go on both sides and rear later (same tape as on DF velomobile). That will really set it off between the two colors of yellows.

I like it, happy with paint job/2 tone. Doing accent stripe on both side and rear with reflective tape like on frt & rear of DF velomobile. Then it will look good and finished. Everything fits. 4 years of building molds and this great velo. Iam happy. Rolhoff and bafang 750watt up front. Great music with 4 exciters.





As seen in above post,,, already started second velomobile which is 4 wheeler. This one will be delivered to doctor next week.
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Edited by - carolina on 08/23/2018 05:19:44
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Toecutter
New Member

USA
57 Posts

Posted - 08/23/2018 :  09:41:30  Show Profile  Reply with Quote
Beautiful work. Any idea how many hours of work it took to build?
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carolina
human power supergeek

USA
1059 Posts

Posted - 08/23/2018 :  11:09:29  Show Profile  Visit carolina's Homepage  Reply with Quote
Nowdays l can make a unibody ready for hardware and paint in 4 weeks of this full canopy style.

Soon l will start the regular man hole entrance velomobile top mold (posts above),,, when that mold is finished l could build one ready for hardware & paint in 15 days.

Hardware and paint takes forever. Builders can install their own styles of hardware and paint. I can ship unibodies cross-country.

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Now your question: ripleys believe it or not:) ive worked every day including holidays and weekends for way over 3 years. Go to first post here on recumbents dot com.

I had 150 thousand views on bentrider before l was banner by brian. Those constant posts tell story from beginning. Recumbents dot com is best forum. Warren does not hate if your right wing constitutionalist, shoot pistols, reload ammo, hunt, fish, vote trump. If you were not born before 1953 it痴 very very very difficult to know America.
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carolina
human power supergeek

USA
1059 Posts

Posted - 08/24/2018 :  23:20:36  Show Profile  Visit carolina's Homepage  Reply with Quote
Install windows with a few tricks:



Nuts, bolts, & hinges.


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carolina
human power supergeek

USA
1059 Posts

Posted - 08/24/2018 :  23:26:45  Show Profile  Visit carolina's Homepage  Reply with Quote
Inside the WAW type rear cowling: i ran the rear lights cable with the cannon plug. The plastic weather guard is held on with 3M strip-calk.


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Edited by - carolina on 08/25/2018 13:10:58
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Tom Schneider
recumbent enthusiast

131 Posts

Posted - 08/25/2018 :  08:47:23  Show Profile  Reply with Quote
Now a test ride and results?

Tom
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carolina
human power supergeek

USA
1059 Posts

Posted - 08/25/2018 :  11:30:25  Show Profile  Visit carolina's Homepage  Reply with Quote
Tom:

Been riden for year lol, got bout 15 different days. One thing paint don稚 change. Page 3, pic shows 2017 November riding to grocery store or near that date.

Built the lowracer and 4 wheeler conversion too while working on this velomobile. [Glance over the 10 pages of this thread for quick timeline.]. Rode many moons without top or rear cowling. Wish post were numbered.
_________________

Velomobile delivered when doctor get back of 7th/vacation. Be watching the 4 wheeler velomobile build, started in above post. That will go lil quicker and the 4 wheeler mule has been riden about a year. Just moving hardware from old metal frame mule to new unibody. Save weight too.
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Edited by - carolina on 08/25/2018 11:57:07
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CincyRay
Starting Member

USA
37 Posts

Posted - 08/25/2018 :  11:56:38  Show Profile  Reply with Quote
Nice job. Seems to me that If you want to start selling these without mechanicals, you would at least want to publish more ride info before you send it over to your first buyer. Why not put together a longer video filmed from a chase car to demonstrate what it can do. Is it fast or slow versus other commercial velos? How about having a more athletic bent cyclist take it out for a spin and see what kind of speeds it can achieve and how noises it is. How much does it weigh? How does it perform with and without the canopy? Is there a plan to look at internal hinges for the canopy? Sure would clean up the look. Thx.
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carolina
human power supergeek

USA
1059 Posts

Posted - 08/25/2018 :  18:46:52  Show Profile  Visit carolina's Homepage  Reply with Quote
Built this tiny 3/16 lip on brake lever. It allows stock micro-switch to remain stock. The thin lil metal lever on micro-switch is usually bent to some shape that will work. Now its out of box working.



Today i put 6mm rivnut in top of rear cowling. This makes it easy to roll velo around at rear with some hardware to hold on too. You can just keep inside or in your pocket.


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carolina
human power supergeek

USA
1059 Posts

Posted - 08/27/2018 :  13:43:59  Show Profile  Visit carolina's Homepage  Reply with Quote
Notha short vid on my channel:

https://youtu.be/W7VZRkNc2PA
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carolina
human power supergeek

USA
1059 Posts

Posted - 09/01/2018 :  20:15:27  Show Profile  Visit carolina's Homepage  Reply with Quote


Needed lil more cutting room, 2 Harbor freight stands, threaded rod, and some PVC. And stands can be used with the rollers they came with. With electric scissors and serrated blades (wish i had had in mid 90痴) its a good table. 3/8 sheet of plastic with worn numbered cutting pad under plastic. Some patterns are 50肺36 which is a yard from compositeenvisions.com. PVC fit perfect in the roll tube compositeenvisions uses. Rear wheel well patterns are 25肺36.

Cheating 11 ounce twill carbon. Tape it then cut it.


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Edited by - carolina on 09/05/2018 17:56:55
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carolina
human power supergeek

USA
1059 Posts

Posted - 09/02/2018 :  16:13:54  Show Profile  Visit carolina's Homepage  Reply with Quote
Layed up one side of three part mold of rear wheel wells today in 2 & 3/4 hours. 4 layer sandwich of carbon only with inserts after second layer.

First layer is hardest, then second layer will behave and stick. Moving and seating the thicker carbon with the wonderful harbor freight gloves. Used slow hardner.



Last layer 25 X 35, just barely enough.

Epoxy clear-coat up in the wheel wells and wax. Keep the road grim off wheel wells & its epoxy from tires. Otherwise epoxy would be suffering over time.
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Edited by - carolina on 10/12/2018 18:46:23
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carolina
human power supergeek

USA
1059 Posts

Posted - 09/04/2018 :  20:15:38  Show Profile  Visit carolina's Homepage  Reply with Quote
The heart of the 4 wheeler curing. 6 hours plus cutting patterns out. All carbon twill.


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carolina
human power supergeek

USA
1059 Posts

Posted - 09/05/2018 :  17:49:44  Show Profile  Visit carolina's Homepage  Reply with Quote
Top and rear of next 4 wheeler velomobile.

https://youtu.be/swZaoa0krGM

Flip top and glass inside tomorrow. THIS TOP WILL BE A PLUG, NOT A TOP. PLUG=MOLD=PART



This man-hole indy car entrance has to be in best place l can get it for seat and head, the front and rear of top will run-out at given locations.
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Edited by - carolina on 09/05/2018 18:01:56
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carolina
human power supergeek

USA
1059 Posts

Posted - 09/06/2018 :  10:52:06  Show Profile  Visit carolina's Homepage  Reply with Quote
Part removal from tools (molds) can be nightmare. This is new Mavcoat release agent. This is 3 part mold bolted together. Made a great rear wheel well system for 4 wheeler velomobile.


https://youtu.be/NmnW23pcq70


If you follow this thread u know this one took a while too. Hell, they all do but getting quicker and nice. Less headaches.

GOT TO TRIM AND SAND EDGES, SAND AND SPRAY CLEAR EPOXY UV UP IN THE WHEEL WELLS.


Trimming amateur parts is SOB, have a steady hand, i use 3 tools from harbor freight. They池e great. Long sleeve shirts, full face respirator, air-hose. I thru that shirt away today:)


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Edited by - carolina on 09/07/2018 14:08:54
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carolina
human power supergeek

USA
1059 Posts

Posted - 09/07/2018 :  07:51:31  Show Profile  Visit carolina's Homepage  Reply with Quote
Next project is new top roll-over at rear bulkhead.
1)I make a plug (master) roll-over with rain gutter down in the mold (one time use), it matches rear inside of new top.
2) Then lay the multiuse new top mold over it.
3)That mold will cleico on and off.
4) l will still be able to make other top (full canopy like yellow velo above) with it痴 roll-over mold on shelf. Just clieco in place and go.



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Edited by - carolina on 09/07/2018 07:55:20
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carolina
human power supergeek

USA
1059 Posts

Posted - 09/08/2018 :  13:22:58  Show Profile  Visit carolina's Homepage  Reply with Quote
Made a plug this morning 10:00 til 2:15. Plug wil temporarily sit into the big mold (above post). This is rear roll-over at rear bulkhead. Where front top meets rear of top at roll-over. Once plug is smooth a mold will be made from it that mates with big mold.



My cut line is rearward more than this line, this top will make a plug for upper top mold made later.


A whole top cut in 4 pieces is tedious to put back together. I had to put together original and re-cut at different location.


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Edited by - carolina on 10/12/2018 18:47:41
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carolina
human power supergeek

USA
1059 Posts

Posted - 09/09/2018 :  08:12:51  Show Profile  Visit carolina's Homepage  Reply with Quote
Video about: Mavcoat release agent on plugs molds parts. Most incredible! New chemistry coming along, hope it keeps coming.

Made this lil plug for roll-over behind head rest. This plug will help with new top project (indy car type man hole entrance on the velomobiel).

https://youtu.be/cxNAxwZwfho

Large rain gutter, plug ready for bondo skim coat, sanding, & primer.

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Edited by - carolina on 10/12/2018 18:48:53
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carolina
human power supergeek

USA
1059 Posts

Posted - 09/11/2018 :  21:27:32  Show Profile  Visit carolina's Homepage  Reply with Quote
This yellow two tone is gone now.

Fitting man-hole top to lower: This top will be a plug for 1 piece mold. Will sit aside and layup lower unibody first, then start on top again.




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Edited by - carolina on 09/12/2018 20:01:09
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carolina
human power supergeek

USA
1059 Posts

Posted - 09/18/2018 :  11:35:35  Show Profile  Visit carolina's Homepage  Reply with Quote
See yellow fine line tape? Cut line.

Nail seated at rear for pulling pink tape.

Shipwrights divider and marker.

Its perfect and allowed 32nd of sanding on each half in future.

Not a laser culture shop here yet. No cnc too. Find the fault in the finished painted pieces.


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Edited by - carolina on 09/18/2018 11:39:29
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carolina
human power supergeek

USA
1059 Posts

Posted - 09/21/2018 :  09:05:02  Show Profile  Visit carolina's Homepage  Reply with Quote
I thought up a way to leave rear bulkhead original on the big unibody lower mold. The black roll-over mold goes to full canopy velo. The fglass one (plug) under it goes to man-hole top.



Standard velo upper/top. Man-hole entrance.


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Edited by - carolina on 02/11/2019 16:29:42
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carolina
human power supergeek

USA
1059 Posts

Posted - 09/23/2018 :  11:51:01  Show Profile  Visit carolina's Homepage  Reply with Quote
Plugs some call the master: i hope more people start making plugs, molds, parts.

DAYS OF WORK MAYBE YOU SEE SOME CHANGES:


Building a floor out of poster board and hot glue to capture a floor of 1/2 to 3/4 bondo that will be sanded to shape. Building up bondo 3 hours.

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Brevity & misspellings rampant.

Without cnc these are tools i use below with bondo, foam, balsa, lauan wood.



1) cleico plyers and cleico痴. (Aircraftspruce.com or The yard)
2) soft tape measures
3) shipwrights divider bought on ebay vintage
4) profile gage on ebay
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Edited by - carolina on 10/12/2018 18:51:20
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carolina
human power supergeek

USA
1059 Posts

Posted - 09/28/2018 :  12:15:26  Show Profile  Visit carolina's Homepage  Reply with Quote
NEW UPPER

Still looks the same but much work: plugs (master) takes forever but the mold (tool) goes quick.



Nice view: and pedal clearance.

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Edited by - carolina on 09/28/2018 12:17:38
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carolina
human power supergeek

USA
1059 Posts

Posted - 10/03/2018 :  09:40:11  Show Profile  Visit carolina's Homepage  Reply with Quote
Grey the orange evercoat for some color wet-sanding on this plug.


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Front of my R&D machine ive used over 3 years, outback is a quattrovelo rear-end. Love a pinion 18 speed german transmission.


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