Building
A Custom Carbon Bike Part 2
|
| July
21, 2002
|
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| Continuing
where we left off, the plug was split in two, damages repaired, each side
was mounted on a flat board, and may layers of glass (not carbon fiber)
laid over the plug. We see the results in the above photo. At this stage,
the plugs are still inside and must be removed. All that is wanted is the
glass impression of the plug sides. The next task is to remove the plugs. |
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| Disaster
strikes! The plugs did not remove cleanly from the glass impression. The
white flaking material is gel coat epoxy which was the first coat applied
to the plugs (prior to the glass build up) and should be in the negative
impression and not on the plug. This set me back some three weeks as I had
to hand repair both sides of the mold. Very painful and time consuming. I
obviously have much to learn about mold making. |
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| I
was finally able to repair the molds. Since they were not as stiff (and
hence straight) I had to ensure the mold cover (see left side) was flat,
straight and would not warp. The finished half mold is on the right and a
strengthened half mold cover on the left. Note the 1/4-20 screws to be
placed around the periphery of the mold. This ensures that the expanding
foam does not warp the entire assembly. Since the half mold is somewhat
flexible, straightness must be ensured by the half mold cover assembly. |
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| This
is the other side of the previously shown half mold cover. This is the
side that the half mold is attached to after carbon fiber is laid in the
cavity. Note the black object in the center of the cover is where the
liquid foam enters, and the objects at the top and bottom is where vacuum
lines are attached. This ensures that the entire cavity is filled with
foam as it sets in 30-40 seconds. |
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| Shown
here is the other half mold cover. The mold cover shows the residual foam
that escapes from the orifices after the vacuum lines are removed. |
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| Shown
here is the corresponding half mold that goes with the half mold cover.
You are looking at the outside of the mold and not the cavity as in the
previous pictures. |
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| Both
half molds (right and left frame) were tested with foam only, without
carbon fiber to ensure that the cavities would completely fill with foam.
The results were perfect. My homework paid off (some 3 different molds and
20-30 samples) as both sides were accurate and true. The blue material is
just tape holding both sides together. |
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| This
shows a view from the rear and both halves separated. The foam offers no
strength in itself, but when covered with carbon, offers great strength as
a complete assembly. |
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| The
time has finally come to produce carbon parts from the molds. The above
and following three photos show right and left sides bonded together to
form what I call the main frame. As was previously stated, the rear stays
will be made separately. The main frame feels incredibly stiff, but only
testing will tell. The main frame weighs some 3 lbs. but it is not
complete and I will not speculate until it is final. Shown above is a side
view of frame #1. Frame #2 will be used to construct the bike. This frame
will be used for other purposes. |
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| Front
view of frame #1. |
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| Another
front view. |
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| The
inside right side of frame #2, which will be used for the bike is shown
here. Completed main frame #1 is behind. The inside is flat and the carbon
of one side is bonded to that of the other to form a vertical spine. Each
half section forms a "D" which results in a very stiff assembly.
|
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| Rear
view of same. |
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| Front
view of same. |
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| The
other half of frame #2 shown here still on the mold cover. The finished
part sometimes sticks to the cover and sometimes to the cavity. It is
always exciting to see what you get. All of the parts were made without
the use of heavy gel coats and will be painted when finished. The next
task is to build the rear section. Below is an attempt to determine the
final weight. It will be constantly updated. |
|
Components
Weights |
Estimated |
Vendor Specs |
Actual |
Total |
|
Frame :: Own
design and Fab |
1816 |
|
|
1816 |
|
Seat:: Optima
Carbon Large |
|
680 |
|
680 |
|
Seat
Fittings:: Aluminum |
300 |
|
|
300 |
|
Fork :: Own
Design and Fab |
|
|
360 |
360 |
|
Stem/Tiller::
Baron |
200 |
|
|
200 |
|
Handlebar::
Baron |
175 |
|
|
175 |
|
Brakes ::
Campagnolo Record |
|
308 |
|
308 |
|
Shifter ::
SRAM 9.0 Shorty |
|
160 |
|
160 |
|
Brake Lever::
SRAM 9.0 |
|
156 |
|
156 |
|
Crank ::
Murray Adjustable Length |
|
465 |
|
465 |
|
Chain Rings::
53 and 42 |
130 |
|
|
130 |
|
Bottom Bracket
:: Shimano Dura Ace |
|
173 |
|
173 |
|
Front
Derailleur :: Shimano Dura Ace |
|
80 |
|
80 |
|
Cassette ::
Performance Forte Pro 12 x 23 |
|
104 |
|
104 |
|
Rear
Derailleur :: Shimano Dura Ace |
|
209 |
|
209 |
|
Chain ::
Wipperman Stainless (3) |
|
894 |
|
894 |
|
Headset ::
Chris King |
|
84 |
|
84 |
|
Cables/Housing
Gears :: Nokon KONKAVEX |
70 |
|
|
70 |
|
Cables/Housing
Brakes :: Nokon KONKAVEX |
50 |
|
|
50 |
|
Rear Wheel::
HED Alps 650 Clincher |
|
760 |
|
760 |
|
Rear Tire and
Tube:: Conti 650 x 23 |
210 |
|
|
210 |
|
Front Wheel
/Tire/Tube:: Sun M14 A/Conti 406x1.25/ 18 x 1 |
|
|
820 |
820 |
|
Skewers ::
Front and Rear |
50 |
|
|
50 |
|
Main Pulley
Guide:: Modified Custom |
100 |
|
|
100 |
|
Hardware::
Aluminum and Ti |
100 |
|
|
100 |
|
Total Weight:: |
|
|
|
8454 (18.6
lbs) |
