Homemade Carbon XC Frame – pics and details as promised!
in your internet travels you probably came across the article written by some spoke length calculator geek called Damon Rinard, who built his own bike out of CF many years ago…
…and you probably know he is now a senior engineer at Cervelo…
Fingers crossed!Posted 4 years ago
Spazzolino – I did try heat shrink wrap, but I didn’t have much success with the results, as sometimes I got over-compression (crushed the foam core) – I found some 50mm cheapy electrical tape, which seemed to work the best as it had a good amount of stretch. I also used the method of pricking holes in it to allow excess resin to seep out. I used clingfilm and expandin foam mainly as a school experiment to pad my coursework a bit – it really didn’t give good results (strong but looked crap)
Crashtestmonkey – TBH I have never actually considered a career with composites, as vehicle dynamics (primarily F1) is my main area of interest. – but I never know where my interest will be in 10 years time!
lol – hadn’t seen the lathe – LOVE IT!!!!Posted 4 years agojamesoSubscriber
Impressed, good work..
Not sure what I’m more impressed with, the ride-able end result or the fact you did it in a garage that makes mine look tidy and not many do that.. I struggle to build bikes there never mind make a frame )Posted 4 years ago
I was looking up info on making some small parts in carbon a while back, feeling inspired to get back onto those ideas now. Thanks – great project + post.
jameso – I will admit I was lucky with the weather and did 99% out the front of the garage as you do need space to work with carbon, I worked on the folding table with green + orange paint. The disassembled jig to the right can also be seen 😀 – if the weather had have been bad I would have cleared the garage out as you need 360 degree access when building. In terms of small parts – I have made my own bash out of a flat sheet of carbon (works great), I did try a bottle cage but that wasn’t as successful – but will try again with a new bottle 😀 (it stuck last time)
FunkyDunc – no foam left in it – I moulded the main tubes around pvc pipe, and the small parts I melted the foam out with acetone – as I did internal cable routing I needed clear routed though the frame 😀Posted 4 years agoAlexSimonSubscriber
richmars – Member
A canoe is currently winning in my head.
Easy. Big block of foam, curved to a canoe shape. Lots of carbon (might be a bit expensive), lots of tape. Dig out the foam when cured.Posted 4 years ago
Carbon fibre isn’t usually used on its own for canoes.
Kevlar is the better bet.
Although to be honest I’m leaning towards a cedar strip construction with glass fibre outside.
yeah – when I looked around oxford brookes uni a few years ago, they were doing the development and testing for these next door to the room I was in so I went and had a look around -They let me have a quick spin on it – and to be honest I was a bit disappointed, but probably didn’t ride it enough to see the benefits and might have been an early prototype. By then I had already started making the bamboo bike trailer for my a-level, so it was a bit late for extra credit/research.Posted 4 years agoboltonjonSubscriber
Fair play mate – sounds like a great Uni project
The best projects i could come up at Uni was designing an electric chair, determining, through statistical analysis, the number of women Bond had nailed and programming a computer to beep ‘Baa-Baa Blacksheep’
Bolton Institute at its very finest 🙂Posted 4 years ago
thought I would update this with the latest turn of events…
so I went to cannock chase today with a few mates from uni, all going well till I have a bit of a nasty pedal strike (dented a m520 pedal kind of hard) so think nothing of it till about 20 mins later where it felt like I had bent a chainring but then realised the BB shell had parted company with the rest of the frame…
It’s repairable at least, just need to go home from uni to access the correct equipment to do it – now this I promise to do a full photo documentation (hopefully)Posted 4 years ago
That’s the bit I was always concerned about on mine. I used a layer of glass fibre between the shell and the carbon, as, in theory, you can get galvanic corrosion between the carbon and steel.Posted 4 years ago
Also, it’s not easy to get a good surface area contact between the shell and the rest of the framecompositeproMember
a decent bond will only occur if you can get the fibreglass to stick to the aluminium anyway ,a bond is only as strong as its weakest element the fibreglass is not the weak element the interface between the aluminium and whatever epoxy or adhesive is used is(some adhesives are not epoxy based)
Google FPL etch (still a bit old) and extrapolate from there or even CAA etch or the phosphoric (sometimes called boeing) process
glassfibre …old hat chapsPosted 4 years ago
compositepro – I have just looked at the failure in a bit more detail and it appears that it is infact the fibreglass-metal joint that has failed, I guess I needed to so a bit better surface prep that a bit of sandpaper before hand! – I have also realised that the way I have designed it the BB shell was only in contact with the carbon around the bottom 50% of it – so an upward impact would just push it up – both these issues should hopefully be fixed in frame version 1.1 🙂
I have looked into both those method, but they seem a little out of reach for a shed-job – so I guess I’ll have to increase the surface areaPosted 4 years ago
to be honest – not sure I have said, so here I go…
Carbon fibre – free 😀 – a composites company donated for a school project I did a few years back (15m^2)
resin – £20 – clicky
pvc pipe for moulding main tubes – £10 clicky
other laminating kit ~ £50 – clicky (gloves,pots,stirrers,brushes,foam for mold, release wax for pipe)
old frame for parts (bb shell, headtube, dropouts) – £?
probably forgotten something major – but will update if I rememberPosted 4 years agolightmanMember
Have you never tried Pallet/Shrink Wrap instead of the tape?Posted 4 years ago
I used tape to start of with, but once I tried the Pallet Wrap, I found it so much easier to use and wrap stuff.
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