I have some plans to make a front splitter, and rear diffuser for my CRX using just flat stock carbon fiber. Some questions I have:

- What weave would be the best structurally?
- Does anyone sell pre-made (epoxy'd and cleared) flat stock cut to size?
- Whats the best way to cut the preped flat stock?

I'd really like to work with the premade stuff since I have absolutely no mold making/carbon fiber building experience. If it's really not that hard I could always
learn, but I'd rather not go through all the trouble of making a molded part.

My other option is to just use aluminum, but I'd much rather use the fibre.

Thanks for any help/advice.
Bryson

 

CF is sold in pre-made panels.... i cant remember where i saw them but when i do ill post it up

 

here ya go http://www.machv.com/cafiplsh.html

found another http://www.hrpworld.com/index....oduct


Modified by ROTARY at 7:43 PM 3/30/2008

 

- What weave would be the best structurally?
Well it depends. Honestly the question leaves out a lot of variables. You won't see much difference between say plain weave and twill carbon weaves of the same weight. There are many processing methods that can be used to give better finished properties. A wet layup part will not be as strong or as stiff as a part that is wet laid and then vacuum bagged. Then a part made from autoclaved prepreg or vacuum infused will generally have even better finished properties. A uni-directional layup with the fiber direction biased in the direction of the load path can prove to be a better choice than fabric but many times the load is coming from many directions so there isn't much relative benefit. Carbon fabrics have a downside in that every time a fiber tow runs over and under another tow it has to initiate a slight bend. This crimp in the fiber bundle is really a weakness compared to unidirectional tape. On the other hand if you have a complex shape it can be difficult to mold uni fibers which is the main idea behind using fabrics, you can easily mold them. A greater variable than the type of fabric you choose is the resin system you go with. Choose the wrong resin system for the application and the fabric type might not matter. Epoxy is used in many structural applications but it is relatively expensive if you buy a quality product. Then you could use vinyl ester resin which isn't quite as stiff but still very durable and less expensive than epoxy. In last place would be polyester resins.


- Does anyone sell pre-made (epoxy'd and cleared) flat stock cut to size?
Yes I build plate all the time and there are many online sources.

- Whats the best way to cut the preped flat stock?
Water jet cutting is my first choice but after that it would be a 1/2" diamond coated dremel wheel.

I would be happy to answer any questions you have if you want to build these yourself. It's not hard per say but the quality really has more to do with how the materials are processed. Around the shop we vacuum infuse a lot so that is what I would suggest but you do need a vacuum pump and some consumables. You can also get reasonable results with wet layup and a roller but it's all relative. How stiff does it need to be, how nice does it need to look etc. Just go with the solution that fits your car and budget the best. Feel free to IM me if you need some tips.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ROTARY &raquo;</TD></TR><TR><TD CLASS="quote">here ya go http://www.machv.com/cafiplsh.html</TD></TR></TABLE>

All but that 4mm thick stuff is going to be pretty flimsy but you could use that stuff as core skins for a sandwich panel.

 

I know Tim McAmis and Quartermax sells it. I bought a sheet from Quartermax to make the EMS and data mounting panel on my RX7 and the whole panel came out to almost 400 bucks. it was like 4x3 or something.

 

itd also save you weight and most likely cost to do a sandwich panel.

how thick do you want the splitter?
do you want the LE radiused?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by dfoxengr &raquo;</TD></TR><TR><TD CLASS="quote">itd also save you weight and most likely cost to do a sandwich panel.

how thick do you want the splitter?
do you want the LE radiused?

</TD></TR></TABLE>

Yeah the sandwich panel definetly sounds like the best way to go. I'd like it to be about 1/4" thick at most, but the leading edge wouldn't have to be radiused. I would think It wouldn't be that hard to maybe get a peice of that sandwich foam stuff, cut it to the form I'm looking for and cover it in the CF.

As for the rear difusser I think I'd rather just cut flat CF and attach it with some aluminum angle.

 

for the rear diffuser, fab one out of sheet metal and release it and preg the part and you have a nice cf part..

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by skellator_thoj &raquo;</TD></TR><TR><TD CLASS="quote">for the rear diffuser, fab one out of sheet metal and release it and preg the part and you have a nice cf part..</TD></TR></TABLE>

What do you mean "preg the part?"

BTW, I noticed you had a splitter for a 90-91 hatchback. Any pics of this?

I also want to throw it out there that I wouldn't mind being a guinee pig for a company looking to produce a carbon splitter for the 88-91 CRX/Civic. I know the market is there.

 

And I'd like to throwout there I wouldn't mind being a guinea pig for any front splitters/rear diffusers for DC2 Integra.

 

preg as in pre-preg. which is fabric you buy pre-resin infused.

i wouldnt mind making up a prototype if someone was local to virginia.

 

i wish i could, i've tried this before, there is interest but no one wants to pay money for good quality cf parts..for example, cf rear diffuser is around 1300 and front splitter is 800

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Boostwerks.com &raquo;</TD></TR><TR><TD CLASS="quote">
I know the market is there. </TD></TR></TABLE>

Im in the market for a new pitcher for our team, you got any of those?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by BB6-213 &raquo;</TD></TR><TR><TD CLASS="quote">

Im in the market for a new pitcher for our team, you got any of those? </TD></TR></TABLE>

lol serious man. As you could probably tell... I gave up. It'd be nice if we could just go out there and have fun. I didn't know that we entered a pre-season expert league (what cassie told me).

 

I can make you one. I make them all the time.

look here
https://honda-tech.com/zerothread?id=2076810

I am getting my masters in composite engineering, so I can help you make a structural piece