How to Make a Carbon Fiber Car Body
Materials You’ll Need
– Carbon fiber fabric (2×2 twill or plain weave)
– Carbon fiber resin (epoxy or polyester)
– Catalyst
– Peel ply
– Release film
– Vacuum bagging system
– Vacuum pump
– Gloves
– Respirator
– Safety glasses
Step 1: Design and Create the Mold
The first step is to design and create the mold that will give shape to your carbon fiber body. The mold can be made from a variety of materials, such as wood, metal, or fiberglass. Once you have designed the mold, you will need to create a release surface so that the carbon fiber can be easily removed from the mold once it is cured.
Step 2: Lay Up the Carbon Fiber
Once you have created the mold, you can begin laying up the carbon fiber. The carbon fiber fabric should be cut into pieces that are large enough to cover the mold. The fabric should be laid up in layers, with each layer being oriented in a different direction. This will help to create a strong and durable body.
Step 3: Apply the Resin
Once the carbon fiber has been laid up, you will need to apply the resin. The resin is what will bind the carbon fiber together and create a solid body. The resin should be mixed with the catalyst according to the manufacturer’s instructions. Once the resin has been mixed, it should be applied to the carbon fiber using a brush or roller.
Step 4: Vacuum Bag the Body
Once the resin has been applied, you will need to vacuum bag the body. Vacuum bagging helps to remove any excess resin and air bubbles from the body. To vacuum bag the body, you will need to place a layer of peel ply over the carbon fiber. The peel ply will help to prevent the resin from sticking to the vacuum bag. Once the peel ply has been placed, you will need to place the vacuum bag over the body. The vacuum bag should be sealed around the edges of the body using tape.
Step 5: Cure the Body
Once the body has been vacuum bagged, you will need to cure the resin. The resin will cure at room temperature, but the curing process can be sped up by using a heat gun or oven. Once the resin has cured, you will need to remove the vacuum bag and peel ply.
Step 6: Finish the Body
Once the body has been removed from the mold, you will need to finish it. The body can be sanded, painted, or clear coated to give it the desired finish.
Tips
– Use a high-quality carbon fiber fabric. The quality of the carbon fiber fabric will affect the strength and durability of the body.
– Apply the resin evenly. The resin should be applied evenly to the carbon fiber fabric to ensure that the body is strong and durable.
– Vacuum bag the body properly. Vacuum bagging helps to remove any excess resin and air bubbles from the body.
– Cure the resin at the correct temperature. The resin will cure at room temperature, but the curing process can be sped up by using a heat gun or oven.
– Finish the body properly. The body can be sanded, painted, or clear coated to give it the desired finish.