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Discussion Starter #1
Well i got the new wheels and the center caps were hideous so i decided to make cf ones, someone asked for pics on how to do it so heres the steps to make the mold.
pic 1 design something and draw it out full scale
2- be handy with rhino or other 3d modeling program(or have an engineering friend)to draw file and then have them write cnc cut program
3- buy $500k 5 axis cnc machine and throw a block of mdf or suitable male molding material
4- have operator cut mold on cnc
5-finished male mold ready for next steps
 

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Discussion Starter #2
this is a male plug to make a female carbon mold so the next steps are
1-cover in release film, this is a self adhesive teflon, teflon needs to be wall paper cut so there are no overlaps since those will transfer
2 center piece done
3 cover flat surface
4 teflon is then vacuum bagged to surface to remove any air bubbles
 

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Discussion Starter #4
plug is now ready to layup on
1 material all ready to go, carbon,peelply,perf and breather and vacuum bag and plastic on table to pour resin- can get messy-
2 resin and hardener are weighed out- mix ratios are critical- this is a high tg resin that will not distort at temps up to 115 degrees celsius
3 thicken up a small batch of the epoxy to fill the finer details in the plug
4 skim the plug with the thickened epoxy to get all details
5 wet out the carbon with the non thickened epoxy
 

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Discussion Starter #5
next apply the wet out layers of carbon to the mold- the laminate should be balanced in weight and fiber direction so the laminate schedule is:
1 rc200 (twill)
1 xc411 (double bias)
2 rc200
1 xc411
2 rc200
1 xx411
1 rc200
this ensures the mold itself will not warp or curve or do anything funky
1-apply layers smooth down with hand to get material to take shape of plug
2 after all layers are down put peel ply on
3 apply perf and breather material - this allows air and extra resin to be sucked out
4 stick in vac bag
5 turn vac on
 

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Discussion Starter #6
vac bag will suck out excess resin and more importantly air in the laminate
series of shots over about 5 minutes to show resin consolidation. vacuum pump runs at 1 atmosphere which is approx 15 psi
 

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Discussion Starter #7
allow to dry overnight then resin is post cured at 60c for 4 hours then 100c for 4 more hrs under vacuum
1 mold is done
2 popped off plug
after a coating with mold release this mold will be ready for pre preg lamination, heat stable and production ready.
NOW i can start to make the pieces
 

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