The enclosed motorcycle by Fred Nelson Fabrication
Carbon fiber Landing Gear Pocket Mould
Here we show the construction of a heavy fiberglass mould required for making a carbon fiber part, the same mould will be used later for plastic forming (although we found that it does not need to be anywhere near this nice for plastic forming) .
We began with cardboard and body filler to get the basic shape of the backside of the wheel pocket. Then, we covered and re-enforced this with light fiberglass mat and resin. Allowed to cure.
Next, we used a plastic bowl to get the shape of the pocket itself. Again, we used light fiberglass mat and resin to cover the basic shape. We waxed the bowl so we would be able to pull it out later (optional). Allowed to cure.
Next, we removed the bowl and completely covered the the cardboard and base layers with multiple layers of heavy fiberglass and resin. We repeat this process, mostly on the inside, until the mold is about a half inch thick.
Lastly, we body worked, primed, painted, and clear coated the outside of the mold with professional high quality automotive finishes (hardened). Allowed to cure one week. Then, we waxed the mold with Meguiar's Mirror Glaze #8 Maximum Release Mold Wax. Now, the mould is ready to make a part.
I pulled a pretty nice carbon fiber part off of this mould (my first try ever), but, it took several days and a lot of money to get to this point. I also broke the mould and had to send it out to be re-body worked and painted just to pull a second part. ..... I decided there needs to be a better way and moved on to exploring vacuum forming. I'm glad I did learn more about vacuum forming the pocket instead click here.
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