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Old 06-22-2007, 05:06 PM   #1
RobK0000
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I started making this lip last Wednesday, it ~22 hours to make, I already finished the lip and thought I would share to you the steps it took to make this real.







Foam Lip after sanding:



Taped up with masking tape:











Hers what is looked like after the glassing?



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Last edited by RobK0000; 07-14-2018 at 05:18 AM.
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Old 06-22-2007, 05:06 PM   #2
RobK0000
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During Bondo Stage:








Dark picture, after primer:







After the CF materials and Clear coat, Also final mounting:

















Good luck feels free to ask questions!



Rob K.

Last edited by RobK0000; 07-14-2018 at 05:19 AM.
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Old 06-22-2007, 05:14 PM   #3
yoshi8me
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looks good!
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Old 06-22-2007, 05:15 PM   #4
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That looks like crap. You should immediately toss it in the garbage can pictured and place it at the curb. (oh, and send me your address and the day you put it at the curb....wait, this won't fit my car....snap!)

When's the group buy start?
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Old 06-22-2007, 05:19 PM   #5
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damn i would have had an awesome installgasm if i did that

nice work!
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Old 06-22-2007, 05:27 PM   #6
legacy2003
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nice man! looks awesome!
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Old 06-22-2007, 05:31 PM   #7
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[Mr Burns]Excellent![/Mr Burns]
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Old 06-22-2007, 06:37 PM   #8
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You got the hard part done. Now its time to pull a mold off that thing and make more.....which is way easier than the way you originally did it.
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Old 06-22-2007, 07:11 PM   #9
RobK0000
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^well i wasnt planning on making more of this exact one, Im going to make a better one sometime soon and sell this one, already got offers and it hasnt been on for 24 hours! lol

Ill post up with new design and what i hope it will look like.
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Old 06-22-2007, 07:14 PM   #10
mbs627
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Hopefully you actually put a little effort into the next one.






Awesome lip, man.
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Old 06-22-2007, 07:28 PM   #11
paosti
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great job...looks good.
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Old 06-22-2007, 07:40 PM   #12
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so you spent $325 bucks........ouch
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Old 06-22-2007, 07:41 PM   #13
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^ have enough material to cover my entire car 3 times over

so i didnt spend that much, make 6 lips just like this, sell them for 300 each, you do the math!
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Old 06-22-2007, 10:07 PM   #14
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looks nice, good job on the write up!
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Old 06-22-2007, 10:32 PM   #15
ST0ICH
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I looks real nice for using with you can get at the hardware store. I love it!!!
Quote:
Originally Posted by RobK0000 View Post
...~Fiberglass cloth material, 4 little bags 36"x36" - hoe depot - $30...
YES!
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Old 06-23-2007, 02:00 AM   #16
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Looks good for your first cf fabrication. Not to be a jerk but nothing that you did was done right...from the fiberglass to the carbon fiber. You should have watched some videos on youtube about carbon fiber fabrication. Your lip will crack, spiderweb, and more than likely break very soon, especially if you touch a curb. The more epoxy you put on there the weaker the whole piece gets. I don't really understand the use of bondo. If you make a good mold, lay up the fiberglass right, you would never need bondo. Besides, CF doesn't stick well to bondo in the long run. It will crack. I'm not trying to bash you but I don't think anyone should use any of the techniques you have used here. The best way to fab a cf lip would be to vacuum bag it, not by hand, and you wouldn't even need to use fiberglass at all, just a few layers of CF. The biggest mistake with Carbon Fiber is too much epoxy and a bad mold. Also, a little trick for getting the carbon fiber to stick to a mold, super 77 stray adhesive...works great and doesn't affect the resin flow at all. Also, the fiberglass lay up, you shouldn't have overlapped it in small 3" strips like that, those are all now uneven areas and potential cracking points. I've been working with Fiberglass, carbon fiber, Kevlar, polyester and epoxy resins for over 10 years and have never used bondo, fiberglass, and carbon fiber together. There is some great vids on youtube about vacuum bagging/infusion and even hand layup like what you did. I wouldn't recommend anyone using this technique.

+ the whole point of carbon fiber is to reduce weight, tons of bondo = heavy as hell.
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Old 06-23-2007, 03:19 PM   #17
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Quote:
Originally Posted by RobK0000 View Post
^ have enough material to cover my entire car 3 times over

so i didnt spend that much, make 6 lips just like this, sell them for 300 each, you do the math!

ow well in that case right on!!!!
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Old 06-23-2007, 04:05 PM   #18
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I oringinally intended on using only fibverglass, but i decied to switch to cf afterwrds, thanks for the info though.

Quote:
Originally Posted by TVC15 View Post
Looks good for your first cf fabrication. Not to be a jerk but nothing that you did was done right...from the fiberglass to the carbon fiber. You should have watched some videos on youtube about carbon fiber fabrication. Your lip will crack, spiderweb, and more than likely break very soon, especially if you touch a curb. The more epoxy you put on there the weaker the whole piece gets. I don't really understand the use of bondo. If you make a good mold, lay up the fiberglass right, you would never need bondo. Besides, CF doesn't stick well to bondo in the long run. It will crack. I'm not trying to bash you but I don't think anyone should use any of the techniques you have used here. The best way to fab a cf lip would be to vacuum bag it, not by hand, and you wouldn't even need to use fiberglass at all, just a few layers of CF. The biggest mistake with Carbon Fiber is too much epoxy and a bad mold. Also, a little trick for getting the carbon fiber to stick to a mold, super 77 stray adhesive...works great and doesn't affect the resin flow at all. Also, the fiberglass lay up, you shouldn't have overlapped it in small 3" strips like that, those are all now uneven areas and potential cracking points. I've been working with Fiberglass, carbon fiber, Kevlar, polyester and epoxy resins for over 10 years and have never used bondo, fiberglass, and carbon fiber together. There is some great vids on youtube about vacuum bagging/infusion and even hand layup like what you did. I wouldn't recommend anyone using this technique.

+ the whole point of carbon fiber is to reduce weight, tons of bondo = heavy as hell.
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Old 06-23-2007, 05:16 PM   #19
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I'm glad your not pissed at what I said ^. Sometimes things come across harsh online. Anyways, if you have a ton of Carbon Fiber left over and you want to really get into making other stuff with it, you should watch some vids or go to the library and rent some books on Auto carbon fiber fabrication.

There are basically 5 ways to do it:
(to simplify things, lets say you are making a a carbon fiber hood)

Wet layup--you would take a piece of cf, place on a flat surface and wet it out with resin, and squeegee out the excess with a roller. Then add another layer of cf on top and repeat the process until you have the desired layers needed. Then you would place the whole thing in the mold and roll it in.
This method is usually only used for making very small and flat pieces.

Dry layup--this is similar to wet layup but you would put the first layer in the mold first and the rest is the same. Again, only works for smaller flat parts.

Pre-preg laminating--in short, the cf is pre impregnated with the resin, you would then cut to desired size, place in mold, vacuum bag it, and bake it at about 300 degrees to cure the resin.

Vacuum bagging--to start you could do either a wet layup or dry layup. Then you would place cf on/in mold, put in a vacuum bag and suck out all the air keeping suction until resin cures. This is a very simplified version, there is a lot of prep for the bag. This method IMO works best for more contoured parts, large and small.

Vacuum infusion--This is the most time consuming and complicated process, and requires some expensive equipment. It is very difficult and there is little room for error. If you get a leak in your bag, you're screwed. It is the same concept as vacuum bagging. However, you place the parts into the vacuum bag without any resin in the cloth at all. Then suck out the air keeping constant vacuum. Then the resin is introduced through tubes and flow material and pulled through the cf material. This is commonly used for making cf hoods. Doesn't work well for extreme contours because it is difficult to get the resin to flow evenly. Again, a very simple definition.

If you get good at this you could definitely make some cash. A Seibon CF lip is about $300-$500. Cost of material for that lip is I'd say under $50. a 50" x 3' piece of carbon is like $70. You're gonna use not even a 1/4 of that for a lip, depending on how many layers you want. Eveyone thinks cf is soo expensive, it's not really the materials that are so expensive it's the time it takes to make the parts. Lots of prep time.

Here is some vids:

(these are some great vids on all different techniques, accept infusion)
http://youtube.com/watch?v=q_fKlDzemPY
http://youtube.com/watch?v=IWiSSLPf6JI
http://youtube.com/watch?v=s12pUg9ypVU
http://youtube.com/watch?v=bb8QnQf72Rg


(Vacuum infusion)
http://youtube.com/watch?v=fJuifMOEGqM

(Vacuum infusion hood)
http://youtube.com/watch?v=zLUnxUw3nnI
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Old 06-23-2007, 05:41 PM   #20
RobK0000
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Thanks for the post up, that helps out alot! Also i used bondo because i did the little strips of fiberglass, it wasnt smooth. So instead of sanding for the rest of my life i used the bondo and pretty much sanded it back down to the fiberglass filling in the holes and bumps with the bondo. there wasnt much of the bondo left on the mold.

Last edited by RobK0000; 06-23-2007 at 05:49 PM.
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Old 06-24-2007, 03:47 PM   #21
JRL
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Quote:
Originally Posted by TVC15 View Post
+ the whole point of carbon fiber is to reduce weight, tons of bondo = heavy as hell.
+1

Not to mention that bondo is a body filler, and not meant to be used in composites. 3M makes some really good vynil ester fillers. Or you can do what I do and make your own filler using tooling resin and Q-cells.
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Old 06-24-2007, 03:56 PM   #22
RobK0000
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bondo works great with fiberglass, not CF. I didnt know this until TVC15 mentioned this to me yesterday. I experianced absolutly no trouble with it.
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Old 06-24-2007, 03:56 PM   #23
scarsofterror
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looks great bro!! now i wanna make one for my bugeye!!
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Old 06-24-2007, 04:04 PM   #24
impreza_GC8
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Its people like you who make me wish I would get off my ass and build things like that. Where can I buy one LOL
NICE WORK!
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Old 06-24-2007, 04:08 PM   #25
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It looks good but thats a pretty expensive DIY no?
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