Since there is interest I will go into detail.
So first off I don't know what the hell I'm doing here so follow at your own risk. Youtube has lots of helpful videos. Here's the ticket to success. Don't be afraid of this stuff, its easier then it looks. If you can place fabric and roll out some epoxy your set. There is no need for fancy tools, pumps, ovens etc. I have a vacuum system but did not use it. The man who taught me this crude method called it a wet layup and he made incredible contraptions. He made composites from a pair of Levis and it was tough as snot. So don't take composites to seriously. Its not a science. Sure a pro could make the same thing stronger for a third of the weight but were talking less then 5lbs here.
Ok so there's two parts to a composite. Fabric and resin. There's tons of different kinds to pick from and it can get pricey. Bondo even has a line of glass and resin at home depot. I would not touch the stuff but I'm sure it would give results. Here in the states I would shop at TAPS Plastics. They will show you what you need and there's even free literature. I had leftover resin and only needed hardener as it only has a year shelf life and mine turned black. I bought west systems 308 hardener. I recommend the slow cure for beginners. The medium puts the pressure on ya with time crunch, fast is for the pros or quick fixes.
The glass I used S2 glass 4533 and two yds got me three layer s. Its tough but I would recommend 5 layers.
So I bought the eps foam insulation board from the home depot. It comes in a variety of thickness. I bought the 1.5". Cut the triangle out, well actually two identical triangles. Then using a router I cut the channels for the frame tubes. You can use a razor as well or even melt it with a solder iron.
Ok that took a whole 20mins. Then you must adhere the two halves. I used that tough stuff spray insulation as I had it and it filled the voids. It actually is sticky ass stuff so beware.
Allright had a smoke and some lunch and we are an hour in. Here's where you can spend 2 mins or two months of your life. Adding shape..... sure if I left it blocky it would look fine and function but sexy curves are much better. I would guess I spent 3hrs a weekday for two weeks tweeking off this frickin thing. Would of gone smoother had I known eps melts from bondo!!! Set me back some hours. So I used a palm sanding block and a router to shape. The hardest part is making that side look identical to this side. At some point I had to move forward else there would be nothing left.
So shapes almost done but I was struggling with the "put bondo down then sand it all the way off" I needed structure. I had the glass mesh for roofing. I spray glued it to the frame. This acted as a chicken wire for the bondo, smoothed imperfections and also gave me a warning layer. So sanding the inside if I see yellow I know I'm close to the shell and to back off.
Allright bondo done, lets get dirty. Allright just remember that you can sand away ugly when its fiberglass so just have at it like a kid on a paper mache volcano. Its pointless to try and get crazy with the templates. Just slap the shtuff on and get it wet with epoxy. Here's why I me the medium cure. It gets tacky quicker so tough curves grab sooner. Just relieve stuff roughly don't start trimming the excess till later. So it takes me a panicked 20-25 mins a layer. The pot life is 30mins so that's perfect. As soon as the layer is on I have a smoke break......
Start the second layer right away. Its easier if its a little tacky but doesn't matter. Then just keep adding layers till your happy. If you let it cure you can't add more layers until you rough up the surface. Its best to get it all in one afternoon.
So after a number of hours the shell will lose its tack. Its soft like taffy. Perfect time to trim the excess. If you trim to soon then its messy, to late and you have to sand it off.
I then used the epoxy and micro balloon filler as a bondo/gelcoat to fill imperfections. Let it cure. Longer the better. At least a week. Then, again how smooth do you want it. Its really easy to spend hours of you life sanding, filling, sanding, rubbing, sanding.... my wife was worried id lost it and was worried I ruined a perfectly good bike! LOL whats up now wifey! !!
So then you paint it. Paint sucks even when a pro does it. You can't abuse it like powdercoat. Thinking bought getting it vinyl wrapped like the cars...
Adam
