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original post: http://www.6thgenaccord.com/forums/showthread.php?t=12691&highlight=carbon+fiber

DIY carbon fiber overlay
I will finish and add more to this as time goes

ok I am going to start this thread off saying that this is not my first time working with
carbon fiber. I have been doing work off and on as a hobby not so much lately but I figured that I should share some of my work since I gave back into my hobby again.

First off you’re going to need to figure out what you want to work with and if the piece is workable. since
carbon fabric is fairly stiff it is not always easy to conform it in the shape you want.

next you will have to gather your supplies
1.painters tape
2.carbon
fiber fabric
3.epoxy, for the resin resin I used west systems 105 resin and 207 special hardener with uv protectant
4.latex or similar material gloves
5.sharp scissors
6.a respirator
7.long sleeve shirts help keep the
fiber slivers out of your arms
8.adequate space that is room temperature and not too humid
9.sand paper 80 grit, 220 grit, 320 grit and 400 grit
10.brushes (something cheap/disposable)
11.black tint (for epoxy resin)
12.digital scale for weighing resin/hardener
13.mixing sticks and cups
14.whiskey/party favors

Next you are going to sand the piece with 80 grit preferably because it leaves nice gouges in the surface of your part for the resin to seep into for a great hold. I put roughly 30-45 minutes into sanding the piece below.

pic 600
Next you will need to wash the part to get rid of any unwanted debris. let the part dry real good, I let this dry over a few days. a few hours in a warm dry place should do however. you want to make sure there is no moisture left on the part before any work continues.

Figure out how much
carbon fabric you need for the piece you are re-working. mask the lines you will be cutting with painters tape and cut the fabric right in the middle of the tape. the tape ensures that the weave doesn't distort and make a mess of itself when cut. It also reduces allot of the waste.

Coat the part with resin evenly try not to get it too thick or too thin. Catch any resin build-up spots and thinned out areas, as the resin cures. it will save you lots of unwanted work (aka sanding).

Let the resin cure until it is very tacky. Remember that when the resin is tacky it will cure much faster than it was previously before B stage (tacky).

Once tacky (wear gloves) lay the fabric down how you want it. you pretty much have one shot to ensure a nice weave. you will most likely need to watch the fabric to ensure that it stays where you want it because the fabric will lift in spots.

Once cured for 12-24 hrs depends on the hardeners pot life (cure time) could be longer you lay down a thin layer of epoxy on the whole area where the fabric is epoxied down and then about a quarter to half an inch overlapped onto the excess
carbon that will be trimmed off

let the epoxy cure until it has been hard for 10 or so hours then trim off the excess
carbon with a razorblade you don’t want to overdo it be careful you could easily cut too much off. you want to leave some excess on there.
here is what my bezel looked like after being trimmed with the razor

pic 601
Next you get your 80 grit sandpaper on a sanding block I used a jenga piece it was handy and small enough to work with this piece. sand evenly on the excess carbon until you have your desired results

Next sand any unwanted excess resin buildup (always happens)
here is what your piece should look like after sanding the resin buildup and excess
carbon.

pic 602

Next wash the debris off of the piece and let dry for plenty long.

up next mix up 5-10 grams of epoxy resin and the black tint. tint the edges of your
carbon piece where you have previously cut

here is an example on where to tint


pic 603

let the black tint cure for another 10 hours and throw down another thin layer of epoxy (no tint) on the carbon fiber very carefully watch for built up epoxy spots and bubbles.

here is what you should have after 2 layers of epoxy and the tinted edges are done twice


pic 604

next up is one more tint job and another coat of resin

after your done with that get out your 220 grit sand paper on a sanding block sand the surface until it is even and smooth. Once that has been finished sand again with 320 grit paper and the sanding block then hit it with the 400 grit and a sanding block again.
while doing these steps be careful not to sand through the
carbon it can get ugly.

once completed check out the part and make sure everything looks good if so you should be ready for clear coat. otherwise you can throw down another very thin layer of epoxy sand it smooth and polish

 

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