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- Wear a respirator because epoxy fumes are bad
- LHR has communal respirators but if you are a germaphobe I recommend you buy your own. You need a respirator and filters
- Respirator: https://www.amazon.com/3M-Respirator-6200-Respiratory-Protection/dp/B007JZ1N00/ref=sr_1_4_pp?c=ts&refinements=p_89%3A3M&s=hi&sr=1-4&ts_id=2257619011
- Filters: https://www.amazon.com/Respirator-Cartridge-Particulate-Effective-Particulates/dp/B0BM99H1CC/ref=sr_1_1_sspa?s=hi&sr=1-1-spons&sp_csd=d2lkZ2V0TmFtZT1zcF9hdGY&psc=1
- Wear gloves and your worst clothes to keep any epoxy from getting on yourself. It is very hard to get off
- If you do get epoxy on yourself, use acetone to get it off. Use this very sparingly and wear a respirator when you are exposed to acetone.
Roles (Easiest to hardest)
- Scrapers: scrape out excess epoxy and make sure the carbon fiber is flush to the surface of the mold
- 6-8 people
- Bucket duty: mixes an adequate amount of epoxy and distributes it in a timely manner
- 2-3 people
- Fabric duty: applies the fabric in the right area so there are no creases, tends to be more experienced members and/or people who cut the fabric
- 4-5 people
- Overseers
- 1-2 people
Step-by-step guide
Pre-Layup
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Layup: We want to build up fabric and resin around in a loop, going from adjacent area to adjacent area. We want the composite to be as smooth as possible, with no air bubbles.
- Have 2 people mix a bucket of epoxy Use a scale mix resin and hardener according to the ratio specified on the resin
- Depends on the brand so read the label
- Apply epoxy to the mold with a paintbrush in the size of the carbon fiber piece you are about to lay down
- Make sure the entire area is saturated with epoxy
- Put the carbon fiber on the epoxied area and press it down very flat until it is flush with the mold
- Apply more epoxy until every single bit of fabric is wet
- We the fabric to be wet but apply epoxy moderately. We do not want to waste any.
- Use a flat scraper to scrape out any excess epoxy from the fabric
- Be gentle and firm at the same time.
- Try to hold the fabric down taut with one hand so it doesn't move around.
- Scrape with medium pressure and be conscious that you do not alter the weave of the fabric, we want to keep that nice checkerboard pattern.
- Move excess epoxy into the next area we plan to add fabric on
- Be gentle and firm at the same time.
- Repeat this process
- On all subsequent layers, tack down carbon fiber and let the resin from the prior layer soak in before you add excess resin. This prevents waste
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