![]() use the same technique on the inside of the part to bulk up any areas that need it and add some carbon to the higher stress points. To help the part fit more like OEM its important to get the mating surfaces the same thickness as the OEM. this is not a big deal for this part because there is a lot of wiggle room and the extra dimensions are almost negligible. because we built the part on the outside of the OEM, technically it will be slightly larger in all dimensions. When it is fully cured separate your new part from the old sacrificial OEM part. it will look ugly but you've got a lot of sanding work to do so don't worry. this will help keep the carbon where you put it and ensure full saturation. take the chip brush and stipple the carbon onto the part. gently sprinkle the carbon onto the part and drip a little resin on top. use some throw away chip brushes and cut off about a inch of the bristles. paint a thin layer of resin onto your part to give the carbon something to stick to. polyester resin will cure in less than 1 hour and the epoxy i use takes almost 24 hours to fully cure. ![]() Mix your resin, i'm using an epoxy resin but you could use fiberglass and polyester to save money and time. try not to mix it or play with it to much as the fibers will start to separate and become a stringy mess like a dust ball in the corner of your kitchen, only bigger. Next i took my carbon cloth and chopped it up into random small chunks. This is for simplicity an alcohol/vinyl mixture that when the alcohol to evaporates it leaves a vinyl film on the part for better separation. this will ensure the resin does not stick to the part.įor added piece of mind i sprayed a little PVA on the packaging tape. The carbon is going to overlay on the top of the part so the next step is to cover the part with packaging tape. Glued in some pieces for a little added strength.ĭo your best to fit the part back into position on the car to ensure you got the shape and fitment correct. i used cardboard and hot glue to rebuild the missing pieces. The first step is to make the part whole again. Some of the sides had been eaten away and holes wallowed out. The part gets beat up from scrapping driveways and potholes and has lost the flat bottom due to damage. The part I made is a small under tray piece that sits under the front left bumper cover on my E93 M3. and the boating industry practiced this with fiberglass years before I was born. if I had a non structural part that had a damaged corner or a miss drilled hole, i would cut up the carbon, mix a little resin and vacuum bag the part. They can pop out parts like nothing.Īs a side note I was using this technique years before Lambo thought of it. to make the parts they have a male and female mold in a press, throw in some "forged carbon" at any orientation, press it and apply a little heat, trim it, drill it and your down. and because the fibers are so short you can get them to contour more difficult shapes with a ton less man power. because the orientation of the forged stuff is super random you can overlay them and overlap them as necessary. the "forged carbon" is made in the prepreg form as well and comes in sheets. any scraps that they have left over can be chopped up into forged carbon as well. ![]() if a manufacturer produces a bad roll of the woven cloth then they could essentially chop it up to make "forged carbon". ![]() picture taking a roll of yarn and cutting the strand into 1/2 inch or so pieces. Forged carbon is basically small cut up chunks of fabric. if the weave ends up crooked or you can see gaps or it doesn't align with an adjacent panel then it is junk, unless you paint it and hide your mistakes. I believe they would mostly use this same process for non structural parts as well or at least a modified version of it. very time consuming and easy to screw up. aside from this, you need the man power and time to place the carbon in the molds, line up the weaves and ensure that the carbon is tight in every corner and cure of the mold. The resin typically requires very high heat and an autoclave to cure. Prepreg carbon is a carbon cloth that is pre saturated with a slow curing resin. Lamborghini predominantly uses prepreg carbon. When Boeing started to build full carbon aircraft the price of carbon went up drastically and companies like Lamborghini felt the pain. I believe this is a marking gimmick so they can cut costs. You can see this carbon in non structural parts like spoilers and interior bits of the new models. OK, Lamborghini apparently, a few years ago "invented" a new type of carbon fiber that they call "Forged carbon". ![]() Scroll down for the DIY or read if your interested in my biased opinions on this technique. ![]()
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