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Old 06-10-2019, 05:06 PM   #1
fartbox420
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Member#: 483915
Join Date: Mar 2018
Location: Canada
Vehicle:
2004 wrx
WRB

Default Composite parts and materials: learning to make carbon fiber parts

Over the last few months i have become increasingly interested in the process of making Carbon Fiber parts and learning about a variety of composite materials and techniques. I am not an expert, but i will share what i am able to learn and the things i am able to create.

The two main materials used are a cloth material like carbon fiber cloth and an Epoxy Resin. There are many types of cloth material, several types of carbon fiber alone. There are different types of resin, but you have to make sure its Epoxy resin. These are the basics.

I Started with the easiest technique, the skinning technique. This basically wetting a part with epoxy then draping a cloth like carbon fiber over it. Making sure it lays flat and be careful not to distort the weave or the finished product have wiggly lines instead of straight lines. For this first piece i skinned one of the 'Exterior Lower Moldings' of my 04 wrx. It sits behind the rear door on the bottom of the wheel well.

I decided to use a Hybrid fabric made of twill weaved Carbon fiber and Kevlar. The fabric i bought had the Kevlar dyed blue. (note: Kevlar is a name brand by Dupont, kinda like Kleenex is to tissue. The generic name is Aramid.)





I know the lighting is not great, i will add other pics when it stops raining out.

Besides the passenger side lower molding, my next piece will hopefully be a front lip. This will be a more complicated process known as vacuum bagging infusion, where i will need to make a mold, add my fabric, and the use a vacuum to pull the epoxy through the mold to create the part.

Comments are welcome.
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Last edited by fartbox420; 06-10-2019 at 05:17 PM.
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Old 06-11-2019, 08:06 AM   #2
Homemade WRX
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Awesome. Keep after it.
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Old 06-12-2019, 11:46 AM   #3
fartbox420
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Here are some better pictures of the Carbon Kevlar. You can see the blue a lot better.





buffing the epoxy is time consuming, so i will put some clear over top to help with the finish and UV protection.
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