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
1031 Posts

Posted - 03/16/2018 :  21:09:03  Show Profile  Visit carolina's Homepage  Reply with Quote


14 sp, 750w, iTunes, usb, led greatness, warm & dry.
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velosRus.com

Edited by - carolina on 03/17/2018 13:06:01
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carolina
human power supergeek

USA
1031 Posts

Posted - 03/17/2018 :  18:21:02  Show Profile  Visit carolina's Homepage  Reply with Quote
Spent 6 hours on this today. Made a rear cowling for me to use in shop for mock up. Trying to make a 8 part plug that will become one plug for the four wheeler rear wheel wells unit. Then make a 2 part mold i hope.

Taped up flange for easy clean up.



Used polyester, fglass, & some kevlar.


Polyester resin mixed with black color additive and duratec higloss additive too.
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Edited by - carolina on 03/20/2018 12:05:33
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carolina
human power supergeek

USA
1031 Posts

Posted - 03/18/2018 :  14:43:11  Show Profile  Visit carolina's Homepage  Reply with Quote
VERY HAPPY WITH THIS FIRST TEST PART:
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Test cowling turned out great, popped out today and learned what I needed about the mold. I wrestled the 3 pieces and won again. I use plastic wedges from Harbor freight and blow 100 psi down in there too for release. This was cheap one with polyester resin, fglass, some left over kevlar pieces.

This waiste piece is one of the 8 pieces iam useing to try to make a “plug” for rear 4 wheeler wheel well set. Went out on a limb a lil and used frekote only with no tr wax. It came out, but next one that is carbon/innegra and epoxy resin. l will use frekote and TR mold release wax.

REAR COWLING FOR MY VELOMOBIEL: (1st test part).

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velosRus.com

Edited by - carolina on 03/20/2018 11:55:47
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carolina
human power supergeek

USA
1031 Posts

Posted - 03/20/2018 :  09:15:48  Show Profile  Visit carolina's Homepage  Reply with Quote
tonight: i will route front cord like challenger, up and over ww, driver can tie off with right hand (zoom in on blue cord, i have pulley that goes in frt.)
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I like the tilt-over canopy like the challenger eu velo. Easy off for maintenance or ride with top off if needed. No leaks on this canopy with heavy downpours.

Enter/exit right/USA. (Unibody velo)


Challenger velomobile: europe (shell on a trike velomobile)


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velosRus.com. 18283

Edited by - carolina on 03/23/2018 20:39:31
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carolina
human power supergeek

USA
1031 Posts

Posted - 03/25/2018 :  13:05:08  Show Profile  Visit carolina's Homepage  Reply with Quote
One unibody ready for wrap and hardware: buy your own hardware like i do and install on your own time snd money like i have in my cf unibody. Sold this one, gotta make another. Love it.

Daily:

Rear cowling takes 2 hours to lay up/2 layers. 20 mins to trim. Then spray primer. Then drill and fit on velo with pop in rivnuts. Then lite prime one more time & wet sand. Then it's ready for wrapper.

Gotta cut 5 windows out of 4x8’ (piedmont plastics $75) sheet this week. A enjoyable job. Not hard.

Clieco Windows in with double sided tape. Then shoot inside perimeter with DOW U-428. Then its water/storm proof but so simple to replace a ruined window. Just cut out with blade, clean and repeat. Polycarbonate or petg could get scratched.

Carbon canopy frame 3 hours to layup. All parts have 1 to 2 days cure time. Fitting frame & canopy to lower is 4 days casual while doing other stuff.

I can make a blk carbon canopy and three carbon “window frame” at nite after 7:00 casually/3 1/2 hrs. Cut lines are scribed into mold. Trimming is a pain, at least 2 hours morning time with wet sand & clean up.

The lower takes at least 5 or 6 days the way i do it. I can stop as i go with peel ply. Carbon & innegra only.

Seat, rear wheel well, and bridge in 3 days including cure.

3 piece frt boom parts/3 days including cure.

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Canopy hardware took a week to design, collect, & install.
Have tested driveline hard with 750watt bafang and also with soft-start firware turned off, no problem, 10 mm chain wheel axles from df. Tested over 16 days.
________________

I held phone correct, can’t figure new iPhone x: love the sound system in this velo.

https://youtu.be/lsC9RAnSpdE

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velosRus.com

Edited by - carolina on 04/19/2018 16:13:18
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carolina
human power supergeek

USA
1031 Posts

Posted - 03/26/2018 :  18:51:09  Show Profile  Visit carolina's Homepage  Reply with Quote
Installed the rubber on the door jam with windshield adhesive.




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Now I have to micro, primer, & wet sand the top. Two-tone vehicle will be an easy wrap @ king signs co, it only 6 pieces.


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velosRus.com

Edited by - carolina on 04/19/2018 16:04:49
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carolina
human power supergeek

USA
1031 Posts

Posted - 03/28/2018 :  09:04:27  Show Profile  Visit carolina's Homepage  Reply with Quote
One person system to wrangle this 8 foot snake. This polycarbonate 4x8 foot sheet was 75$ out the door.


I got a system. See the padded fender stand bumping up against the sheet?,, gotta have that to hold it/scratch proof. (2) ya gotta hav the orange tube taped full length/step 1. The 9" long reach blk clamps on orange tube at both ends. This sheet is 8' long.



1)orange tube fglass came on
2)buy large handle cutter/scribe for plexiglass @ Home Depot
3)6 foot metal ruler
4)9” long reach clamps /Black in photo from harbor freight.
5)padded stand to hold plexiglass roll up/Harbor Freight.
6)poster board patterns.
7)leave mush as possible of white cover on plexiglass till mounted in window frame.
8)this polycarbonate is good stuff. I found hour away.
9)have enough to do another velomobiel @velosRus dot com
10)only way to cut compounds curves on thin plexiglass. (Vid below, best ive found).

https://youtu.be/XPlbZdwQ2AM
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velosRus.com

Edited by - carolina on 04/11/2018 08:39:02
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carolina
human power supergeek

USA
1031 Posts

Posted - 04/02/2018 :  18:04:26  Show Profile  Visit carolina's Homepage  Reply with Quote
Ran a test from duratec reps. Oh yes, another world. Using duratec instead of gelcoat.
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This scrap test mold I sprayed with poly vinyl alcohol then 6 coats of TR mold release wax from ebay, a industry standard.



This finish is all i need:



Two small test pieces: one fglass kevlar & the other is 11&7 oz carbon fiber.
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Well that is bat**** incredible! Best camera i have.
1)PVA
2)6 coats of TR
3)duratec sunshield & higloss additive
4) one kevlar & fglass
5) one cfiber
6) epoxy from composite envisions

Thanks much guys: when u take a novice and help em, its your most reward as time passes.
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Getting close to finishing primer and wet sanding upper: bubble wrap off soon.



Wrap is not vinyl as you think, its super thin. Will show a hair.
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velosRus.com

Edited by - carolina on 04/02/2018 19:28:54
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carolina
human power supergeek

USA
1031 Posts

Posted - 04/04/2018 :  18:59:26  Show Profile  Visit carolina's Homepage  Reply with Quote
All day today I prototyped a way to install long side windows.

Monday, will buy thinner petg 0.30 for side windows. The polycarbonate 0.40 is to stiff for side windows.

Will use 0.30 polycarbonate for front next time.
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velosRus.com

Edited by - carolina on 04/19/2018 16:01:15
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carolina
human power supergeek

USA
1031 Posts

Posted - 04/06/2018 :  17:57:44  Show Profile  Visit carolina's Homepage  Reply with Quote
Cutting kevlar: 1/4” fine line tape, tape wets out. Zoom in,, see blue tape is 95% cut off. CUTS LIKE A DREAM SUPER STRAIGHT. Use clear masking or fine-line tape if ya find some.

Like WAW rear cowling: gelcoat, (i use duratec clear) then thin 1 layer of fglass, then 1 layer of kevlar. Thats it! Super strong and light. Mold prep is: frekote, 7 coats tr mold release, then spray coats of pva mold release, then duratec sprayed and allowed to dry completely before fglass/kevlar.




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Duratec make everything easy and saves so much time preparing for paint or wrap. Not using gelcoat.







velosRus.com

Edited by - carolina on 04/06/2018 18:00:26
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carolina
human power supergeek

USA
1031 Posts

Posted - 04/08/2018 :  18:39:44  Show Profile  Visit carolina's Homepage  Reply with Quote
Even patterns cut, took 6 hours. Second one l made, kevlar and fglass. Some carbon around perimeter.. Orange is peel-ply, will cure for two days.



I needed lil thicker fglass and lil thinner kevlar. Next time i will use 2 large pieces of each and trim the waiste for something else. Will be much quicker. Getting good at spraying duratec sunshield.
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velosRus.com

Edited by - carolina on 04/08/2018 21:36:01
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carolina
human power supergeek

USA
1031 Posts

Posted - 04/11/2018 :  08:47:40  Show Profile  Visit carolina's Homepage  Reply with Quote
Monday i bought petg for side windows and its great fit with no warping



Also finished 3 window frame for front with polycarbonate and DOW u-428. Water-proof and want come out but easy to replace if damaged.


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velosRus.com

Edited by - carolina on 04/11/2018 08:49:06
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carolina
human power supergeek

USA
1031 Posts

Posted - 04/11/2018 :  10:18:54  Show Profile  Visit carolina's Homepage  Reply with Quote
Another tag team match with the plastic wedges and putty knife on the mayflower blanket. Plastic wedges & I won! Kevlar/fglass rear cowling held with 2 fingers. Will the customer mash it in:)

Wet sand, spray thin coat of that blk paint on lower velo, wet sand again and then fit with rivnut kit & screws to rear bulkhead . Trim jig for rear wheel.


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velosRus.com

Edited by - carolina on 04/19/2018 15:49:14
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carolina
human power supergeek

USA
1031 Posts

Posted - 04/16/2018 :  09:15:55  Show Profile  Visit carolina's Homepage  Reply with Quote
Top and rear cowling fitting:


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carolina
human power supergeek

USA
1031 Posts

Posted - 04/17/2018 :  20:16:48  Show Profile  Visit carolina's Homepage  Reply with Quote
Forgot to paint roll-over in prep for wrap:



Love this pic:


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carolina
human power supergeek

USA
1031 Posts

Posted - 04/19/2018 :  15:48:11  Show Profile  Visit carolina's Homepage  Reply with Quote
Ran out of black primer. Wet-sanding for wrapper guy. Bunch more touch up wet-sanding.


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carolina
human power supergeek

USA
1031 Posts

Posted - 04/22/2018 :  18:56:09  Show Profile  Visit carolina's Homepage  Reply with Quote
To the grocery store.


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Terry
New Member

Canada
57 Posts

Posted - 04/23/2018 :  10:23:35  Show Profile  Reply with Quote
Looks good Mike.
Are those WAW mirrors?
Any pics of how they fit together?
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carolina
human power supergeek

USA
1031 Posts

Posted - 04/23/2018 :  12:46:43  Show Profile  Visit carolina's Homepage  Reply with Quote
Those i bought from velomobiel.nl in yellow. They swivel and mount w/ 2 stainless washers, star washer & nut. Just drilled a hole.

The box:


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velosRus.com

Edited by - carolina on 04/24/2018 16:25:06
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carolina
human power supergeek

USA
1031 Posts

Posted - 04/24/2018 :  16:14:50  Show Profile  Visit carolina's Homepage  Reply with Quote
Laying up last 15” of lower for shop use and to make 4 wheeler rear wheel wells plug. It will also make new rollover for new top. Need both, l love the full canopy for cool & cold months.

Took all day to spray & wait spray and wait 6 times, cure morning an ready to layup tomorrow. PVA down, then duratec clear. It want stick, probably bout fall out of mold. Cure couple days. I use duratec clear sunshield instead of gelcoat, love it. I put in some duratec higloss additive and a shot of duratec thinner to spray.



The 2018 top i started. Make a plug from this.


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velosRus.com

Edited by - carolina on 04/24/2018 16:19:09
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carolina
human power supergeek

USA
1031 Posts

Posted - 04/25/2018 :  15:49:59  Show Profile  Visit carolina's Homepage  Reply with Quote
SPENT PART TO BE USED IN SHOP:

4 hour layup, 2 & 1/2 hours cutting patterns. 4 more hours prep time, i put a foam rib in front.
1) part can be used to fine tune swing arm rear wheel well plug.
2) also to make new rollover plug for new man-hole entrance top.
3) and to use to make plug for quattrovelo rear wheel wells.


__________________

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carolina
human power supergeek

USA
1031 Posts

Posted - 04/28/2018 :  19:17:22  Show Profile  Visit carolina's Homepage  Reply with Quote
Big plug to make 3 plugs.



1)
https://youtu.be/QmpxTkgQ-2c

2)
https://youtu.be/I8_Cr7rHndE
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carolina
human power supergeek

USA
1031 Posts

Posted - 04/29/2018 :  17:12:03  Show Profile  Visit carolina's Homepage  Reply with Quote
Grey plug finished ,taken out of mold 2,may.. Now work on 4 wheeler rear ww’s plug, May be 2 plugs/2 molds, not sure yet

Rear wheel well plug for the 3 wheeler. I built this plug bout a year ago but decided to redoo the flange.

PLUG=MOLD=PART


Best tool in shop: boat rights divider found on ebay: got idea from Lou. Ya can’t quit watching his vids.
https://youtu.be/6xpnWQVM2C0




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velosRus.com

Edited by - carolina on 05/02/2018 20:27:36
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carolina
human power supergeek

USA
1031 Posts

Posted - 04/30/2018 :  20:25:13  Show Profile  Visit carolina's Homepage  Reply with Quote
Configured plug today as is in velomobile: now for 4 wheeler.

Trying one of these: wbt-1 the best so they say: i have ordered blde M from uk, serrated blade for kevlar. Will extend life of motor.

[oh, l love this tool]


Constantly changes to rear wheel wells.






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velosRus.com

Edited by - carolina on 05/04/2018 13:53:52
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carolina
human power supergeek

USA
1031 Posts

Posted - 05/04/2018 :  13:59:17  Show Profile  Visit carolina's Homepage  Reply with Quote
With any luck l can pull off a plug for 4 wheeler. Unibody narrows a rear cowling.

Try to shove this rear-end into velo:








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