Total time: 12 hours
- Started 8 PM and ended 8 AM
Materials used
- 4 ply carbon fiber
- 1 layer of Gurit foam core (find exact type)
Step-by-step guide
Mold-Prep
- Sanded fiberglass mold to 400 grit with orbital sanders and used Bondo when needed
- Applied 5(?) layers of wax
- Applied __ layers of PVA sprayed with a paint gun
Layup
- Applied 2 layers of carbon fiber and epoxy
- Applied Gurit foam
- Applied 2 more layers of carbon fiber and epoxy
Post-Processing
- Demolded by sticking a metal ruler between all the edges of the fiberglass mold and carbon fiber mold and it was extremely easy to pry off after that.
- Need someone pushing down while you push up
- Peeled off PVA
- Sanded to 320 grit with orbital sanders and used Bondo when needed
- Learned a neat trick from Tessa on electric; you can fill holes with resin and then put clear packing tape on it
- Ended up using 80 grit orbital sanders on resin-patched spots and sanded through 2 layers of carbon fiber into the foam. Have to be more careful next time
- Cut the lip off the composite with a dremel
Future reference & lessons learned
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