Zipper
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Cutting out carbon fibreI'm looking to make some custom carbon fibre shock towers for the Durga which will move the shock mounting holes up 5mm. This will enable me to use the TRF501x shocks without having to put lots of limiters inside them.
I have a sheet of 3mm carbon fibre and am itching to make the towers, from templates I have made from thin card.
I wanted to know if anyone else has had a go at cutting carbon fibre and if so, any tips?
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LBC
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I take it you're using a bowsaw?
If so: saw slowly, keep the blade upright/level and, most importantly, use the whole length of the blade with each cut.
Drill the corners first, obviously 
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Zipper
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| LBC wrote: | I take it you're using a hacksaw?
If so: saw slowly, keep the blade upright/level and, most importantly, use the whole length of the blade with each cut. |
I thought I'd give Ben's Dremel a run out!
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LBC
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In that case: Drill the corners first (as close as possible) and take your time- slow is quicker!
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Alex
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You were probably already going to, but remember to use a face mask as carbon dust is nasty stuff.
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Zipper
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| henga wrote: | | You were probably already going to, but remember to use a face mask as carbon dust is nasty stuff. |
Would this be ok?
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Alex
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That will do it. 
Is this a small insight into what you get upto at home?
(I'm not really shocked or surprised)
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LBC
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BRILL!! HA-HA-HA! (Emoticon won't work!)
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Zipper
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| henga wrote: | That will do it.
Is this a small insight into what you get upto at home?
(I'm not really shocked or surprised) |
You should see the mask the missus has to wear!
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BenH
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| Zipper wrote: | | ....You should the mask the missus has to wear! |
I heard it was a balaclava backwards. Something about being easier to imagine being somewhere else
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BenH
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 ATTENTION
If you are thinking about buying Carbon Fibre Sheets and cutting your shock towers, chassis or anything else out of it DON'T!!!
The £4.00 you MAY end up saving is not worth it - really not worth it!
If you really really really want to make your own. Buy carbon woven sheets, cut with scissors to suit mould, drop in resin and be done. This long winded way is nothing compared to cutting your own.
Firstly you will need masks, which as you breathe through, filter up into the safety glasses, fogging your vision. Dremels on full tilt and 4 well sanded fingers later you hold, in your reduced hand, shock towers that look like they were shipped in from the planet Wonk.
Then there is the skin. The irritation to the skin as little tiny carbon splinters irritate your arms.
And finally, the mess . From two tiny little shock towers - the dust - my god the dust! After finishing, I felt compelled to start my own Colliery Brass Band
Now where did I leave that strumpet! 
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andyem
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That went well then?
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Zipper
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Good old Ben sort of took over the cutting out of the towers... I think he felt I was useless with the Dremel?
How about the results?
I think we did pretty well. I fitted them to the Durga last night and they fit perfectly. They also do exactly what was intended in moving the shock location 5mm higher.
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BenH
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My arms are still itching!  Lots of red dots - Those nasty nano-bots, they're eating there way through.
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BenH
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| Zipper wrote: | Good old Ben sort of took over the cutting out of the towers... I think he felt I was useless with the Dremel?
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I am looking forward the results. While you wern't looking I scored a hairline crack in the carbon, which if my calculations are right should be enough for 2 laps.
When are you going to test them to see if they do the job?
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Zipper
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| BenH wrote: |
When are you going to test them to see if they do the job? |
A secret testing session is planned.... 
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