www.recumbents.com - Carbon mold/tool for lower&upper enclosed velo
www.recumbents.com
www.recumbents.com
Home | Profile | Register | Active Topics | Members | Search | FAQ
Username:
Password:
Save Password
 All Forums
 www.recumbents.com
 Velomobiles
 Carbon mold/tool for lower&upper enclosed velo
 New Topic  Reply to Topic
 Printer Friendly
Previous Page | Next Page
Author  Topic Next Topic
Page: of 14

carolina
human power supergeek

USA
1059 Posts

Posted - 05/04/2018 :  14:13:28  Show Profile  Visit carolina's Homepage  Reply with Quote
Probably will have to be a open wheel well at rear. Wanted to keep it closed partially. But that want be so bad.

I made 8 pieces just to make this plug even if it’s one or two piece plug. Build these into one and fit them down in there.

Mold will be pulled out of the belly of this huge plug. I made a 3rd of the velo to make this plug.



Trimming, bid plys, bondo in and out. Then cut each ww in 4 location and form again. What would we do without cleicos and masking tape.



Plug=mold=part
——————————

The quattrovelo rear-end is like a 70’s ford pick up truck. Straight axle with springs (mini air-bags) and shocks. Traction bars and sway bar too.

So, the top and bottom of wheel wells haf to tilt in at top and bottom for tires at steep entry curbs, drive ways.



______________________________

velosRus.com

Edited by - carolina on 05/04/2018 18:05:12
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/04/2018 :  20:38:41  Show Profile  Visit carolina's Homepage  Reply with Quote
There’s room for trunk in 4 wheeler: but i like bob tail too.



__19656_________________

velosRus.com

Edited by - carolina on 05/13/2018 10:27:39
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/07/2018 :  18:16:29  Show Profile  Visit carolina's Homepage  Reply with Quote
Days left on these 2 plugs: plug=mold=parts.

Making plugs for rear ww’s, getting closer. Taller than frt ww’s.

WW has to tilt inward at top and bottom too. Also cut very bottom and added 2” of fiberglass/held together with pieces of wood & hotglue till tomorrow. Top 1/3 is cut and tilted in. These will be female plugs. These will be shiny buffed duratec inside of wheel wells, not outside with the magic of bondo & duratec.
———————-

velosRus.com

Edited by - carolina on 05/13/2018 20:47:20
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/12/2018 :  20:33:21  Show Profile  Visit carolina's Homepage  Reply with Quote
Cleico city. It’s getting close for many moons of bondo: people build plug many different ways. No CNC stuff here. Huge plug to make 2 small molds.

4 wheeler wheel wells plug. Will be two small molds



Finding some bases down in there front and rear of bulkhead of which lower bulkhead will be cut out this week. That’s where axle goes.
___________________________________________

velosRus.com

Edited by - carolina on 05/31/2018 12:35:22
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/13/2018 :  10:25:25  Show Profile  Visit carolina's Homepage  Reply with Quote
Takes alot of patience and thinking for amateur’s like me. Make changes but ya haf to keep studying. Try to think about maintenance and easy to extract rear-end. I will do a rear install of rear-end.

BOB-TAIL:


Take off wheels and traction bars and install thru oval holes in wheel wells from rear.


——————————

velosRus.com

Edited by - carolina on 05/31/2018 12:36:12
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/13/2018 :  17:48:18  Show Profile  Visit carolina's Homepage  Reply with Quote
Plug getting smaller. Today was first day with some structure. I took off the cowling. This thing will be a big plug in storage soon l hope. ALL OF THE SHINY WORK WILL GO IN THE TWO WHEEL WELLS AND ON BELLY! What you see now in appearance want change much. Hope to pull a 2 part mold from underneath. The finished ww part goes into velomobile unibody rear with dow u-428 like all other standard velo parts from all composite velo companies.



I cut the bulkhead out now 80% and the air-bag holes and axle holes. There will be a floor from middle floor backwards then vertical 6”s.


———————————-

velosRus.com

Edited by - carolina on 05/31/2018 12:39:47
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/14/2018 :  11:53:03  Show Profile  Visit carolina's Homepage  Reply with Quote
DONT LET PLUGS BOTHER YOU, amateur ones are always ugly on one side.
————————————-

Had to make full scale template (quattrovelo aluminum rear-end) this morning to see if i can get the rear-end in between wheel wells. And the orange stock cut-out in WW’s. The orange stock axle hole pattern has fingers on to help insert wide axle. I DID LEARN YA CAN INSTALL UPSIDE DOWN (trick) THEN ROLL IT OVER BACKWARDS. Looks good. Whewww!



If ya had pic of quattrovelo. The holes i cut look like this flipped on both wheel wells so you can get the long axle in tight place.



Its in: my axle holes will have rubber slotted cover.


_____________

Next lil project is to build 4 layer carbon floorboard at rear. Last 1/3.
——————-

velosRus.com

Edited by - carolina on 05/15/2018 11:50:18
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/15/2018 :  19:14:50  Show Profile  Visit carolina's Homepage  Reply with Quote
Ae lord son, kilt! :) This black floor plate @ rear there is last mechanical fixture of plug. Scrap cfiber down in there with 1/8” foam underneath. Now i can leave rear cowling off if l want. It helps structure though for finishing work. My scrap carbon always gets used up. The inch & 1/4 flange sticking up will be an adhesive area.


———————-

velosRus.com
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/16/2018 :  12:51:55  Show Profile  Visit carolina's Homepage  Reply with Quote
Now cosmetics work on half belly from foam up and the two wheel wells. Weeks for me. Rear cowling out of the way now.



Built in 4 more hard points this morning:



Shop mule:

https://youtu.be/Od_dz3G3yfg
—————————-

velosRus.com

Edited by - carolina on 05/17/2018 12:08:54
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/20/2018 :  15:59:00  Show Profile  Visit carolina's Homepage  Reply with Quote
Left lower inside, other side tomorrow.

https://youtu.be/k5U8evBlY2A


___________
TOP AND BOTTOM OF INSIDE WHEEL WELLS:
more knee breaking work this morning in driveway and inside. You can see one side complete and other curing. L & R bottom of wheel wells are tilted in now, clearance of wheels for the straight axle wheel loaded over hump in the road. NEXT I WILL TILT THE TWO TOP FIVE INCHES INWARD MORE. THAT WILL BE EASY AND NEEDED MUCH.


—————————
velosRus.com

Edited by - carolina on 05/22/2018 21:50:02
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/23/2018 :  11:50:17  Show Profile  Visit carolina's Homepage  Reply with Quote
Rear support wall in now for 2 shocks and 1 sway bar at rear of whole hardware unit.



My unibody 4 wheeler option (other than 3 wheeler) is more like POD velomobile than Quattrovelo because l have removable rear cowling like WAW velomobile.
———————————

velosRus.com

Edited by - carolina on 05/23/2018 11:52:55
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/23/2018 :  17:28:46  Show Profile  Visit carolina's Homepage  Reply with Quote
More headaches, hehehehe but it fits in there. Keep trying to find a seat for all the hole locations. More work.




Couple more fixes to lower the axle a lil’: I’ll do more vertical ww molding later after bolt hole locations.
_______________________

velosRus.com

Edited by - carolina on 06/01/2018 21:33:55
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/24/2018 :  14:33:58  Show Profile  Visit carolina's Homepage  Reply with Quote
No rear der..

I like the hilgo rear floor shfter: ordered one! Zoom in, it will work on four wheeler.



It will go in floor of unibody behind seat:


———————————-

velosRus.com

Edited by - carolina on 05/24/2018 14:36:36
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/24/2018 :  18:10:43  Show Profile  Visit carolina's Homepage  Reply with Quote
All hardware is in the plug and bolted. I have to add some fglass to two front holes closest to ya, bout 1/2” , i measured wrong. And iam designing my own top mounts for top of air-bags. See the lil’ mini air-bags? [Continential tire makes the lemon size air-bags that hold 80 pounds]. If you love to take hard curves & turns, this hugs the road like its on a track. Its like Christmas with this project.


—————————

velosRus.com

Edited by - carolina on 05/24/2018 18:39:58
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/26/2018 :  11:31:58  Show Profile  Visit carolina's Homepage  Reply with Quote
Morning work


https://youtu.be/CbjJSordCTc
——————-

velosRus.com

Edited by - carolina on 05/29/2018 19:34:55
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/26/2018 :  17:18:01  Show Profile  Visit carolina's Homepage  Reply with Quote
Prepping big mold for summer velo: sanded left ww this afternoon and washed mold outside, do other ww tomorrow. Will spray both front WW’s with grey duratec primer, sand and buff to hi-gloss. Duratec is made to refurbish molds. And when ready for cf part i use duratec clear sunshield instead of gelcoat.

Summer velo, low walls at hip level and no top, but velomobile hardware.

————————-

velosRus.com
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/27/2018 :  16:01:34  Show Profile  Visit carolina's Homepage  Reply with Quote
Air-bag aperture/bubble in right ww. Othe Wheel well at 6:00. Floating air-bag clearances.



With electric scissors, cut 6 circles so smooth and easy it’s laughable. If your doing alot of fabrics buy the wbt scissors.


_____________________

velosRus.com

Edited by - carolina on 05/27/2018 16:06:17
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/28/2018 :  15:50:08  Show Profile  Visit carolina's Homepage  Reply with Quote
Built in the last L&R hardpoints in the Wheel wells. I used white plastic angles with tr & pva release. These are air-bag top mounts. I can make thes from aluminum or build a lil mold to make them with carbon.



White plastic will become trash soon.



Now i haf to make the ww plug look like this below. Then pull a male mold. Iam using male mold and not female wheel well mold like below. And mine are one 2 piece mold that bolts together.



Bondo & sanding, then coats of duratec & polish.
____________________

velosRus.com

Edited by - carolina on 05/29/2018 15:18:26
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/29/2018 :  19:18:18  Show Profile  Visit carolina's Homepage  Reply with Quote
Temporary white plastic things did the job and made the seated mold for the bracket. Well, iam making the 2 brackets out of carbon twill in shop. Much better and lighter that aluminum. It would cost to get two made and custom welded (&haf to wait couple days). Lessons from the great Daniel Fenn. Two outside pieces are tilted out. Part will look good, pop out easy, and weigh less with carbon.


Wet sand & polish tomorrow:


This is Duratec grey used in composite mold industry. Check out youtubes. The inside of WW’s will be duratec polished after many moons of bondo & sanding. This lil mold is square school room floor tile & bondo sanded. The thick coat of duratec brushed on. Wet-sand and dremel polish a lil’. I put scrap fglass on back of this lil mold to make it last forever strong. Duratec grey polishes to 80%, look like million dollars. For real fine finishing, spray last coat and add duratec thinner and duratec hi-gloss additive. I can sand that with 1200/1500/2000. Buffs incredible. This mold looses on both sides, the glossy side will never be seen. And this side will be carbon. But if you need a gloss part, I’ve had great luck with duratec products.

Made test : fglass/8 ounce/twill/7 layers. This one will be quick polyester resin.



PVA poly vinyl alcohol peels off.

______________________

velosRus.com

Edited by - carolina on 05/31/2018 16:41:14
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 05/31/2018 :  16:31:34  Show Profile  Visit carolina's Homepage  Reply with Quote
Once fitted you can scribe the mold and never hunt drill holes or trim lines again. I run all trim lines with hack-saw. No heat and easy, then dry sand. Hit round part with small barrel sander.



Heres a carbon one, 4 layers of 11 ounce twill. The L & R vertical sides are angled outward. Base is 90 degrees to WW.




NOW I CAN SCRIBE THE MOLD WITH FINISHED PART. IAM LUCKY, THESE TWO PARTS ARE INTERCHANGEABLE. SCRIBE AWAY!
————————— 20700




velosRus.com

Edited by - carolina on 06/01/2018 12:36:40
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 06/01/2018 :  11:40:08  Show Profile  Visit carolina's Homepage  Reply with Quote
quote:
Originally posted by carolina

One hard thing to learn is: dow u-428 and carbon fiber, i never understood the strength of both till l worked with both many moons and you will not either. I’ve seen honeycomb, wood,foam,aluminum,soric, sandwiched between carbon,, it’s not needed in our world of recumbents and unibodies. Twill, uni, and biaxial carbon is all that’s needed. You want to stay light, you understand that velomobiels are flimsy in certain areas and are suppose to be. One thing that is sandwiched between carbon fiber is INNEGRA. Keeps carbon fiber from exploding from car bumber, tree, etc..

The original was tiny, aluminum, and hard to get a wrench down there with airbag installed. I wanta make as many aluminum parts from carbon fiber as i can in my shop. Saves huge time ,gas, and money. No other machine or welding shop needed. Ala Daniel Fenn.


_________________________
Brevity & misspellings rampant:

velosRus.com



velosRus.com

Edited by - carolina on 06/01/2018 11:46:38
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 06/01/2018 :  21:18:55  Show Profile  Visit carolina's Homepage  Reply with Quote
Masking for grey duratec, all the middle will be grey and polished like rear bulkhead. Lil’ more dry-sanding tomorrow. Then pic a time to spray few coats outside.


Carbon WW’s will go in rear of unibody:

——————-
velosRus.com

Edited by - carolina on 06/01/2018 21:36:41
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 06/05/2018 :  15:54:24  Show Profile  Visit carolina's Homepage  Reply with Quote
Plug shaping started. Using different heads. Porting tool heads and woodwork sanding heads from MDI.


—————————-

velosRus.com
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 06/08/2018 :  15:17:22  Show Profile  Visit carolina's Homepage  Reply with Quote
Another mod in floor:


———————

velosRus.com
Go to Top of Page

carolina
human power supergeek

USA
1059 Posts

Posted - 06/11/2018 :  09:56:59  Show Profile  Visit carolina's Homepage  Reply with Quote
Tons of boring filling and sanding for couple weeks or more. Get back soon. Prepping lower unibody mold for another unibody too.

Layers and layers of bondo on these two bottom panels, then sand all off flat. Layering cab-o-sil and epoxy inside wheel wells each day and sanding.


________________________

velosRus.com

Edited by - carolina on 06/11/2018 18:04:23
Go to Top of Page
Page: of 14  Topic Next Topic  
Previous Page | Next Page
 New Topic  Reply to Topic
 Printer Friendly
Jump To:
www.recumbents.com © 2019 www.recumbents.com Go To Top Of Page
Snitz Forums 2000