DIY Carbon Fiber Wrapped Parts

[Fastbird]

Cliche' I know, but here's the twist: I'm thinking of doing the wrapping myself. I've done the studying and know HOW to do it, but have never done it. Has anyone done this themselves??? FYI this is for my wife's 99 Celica and I'm going to get my practice on that (red and black 3x3 twill in there). Then I'm going to move to some small but tasteful parts inside my Vette (silver 3x3 twill in that one) to compliment.

Just curious if anyone has done this on their own, successful or not, and if you had any tips or tricks to share?

[bottledbird68]

No advice here but in for updates since I've been interested in doing this myself

[chevy42083]

No real info, but I can say it is definitely possible... but the material still isn't cheap.

I know of some guys who used vacuum forming to make their own R/C car bodies out of carbon fiber... as well as a few small parts. I know it's quite possible to do at home using a shop-vac, a homemade mold, and I believe some fiberglassing resin. The weave itself will still be your main cost.

[bricez28]

im gunna jump on the "i have no useful infor for this thread but am also curious" bandwagon

[Adam]

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[Fastbird]

Think I'm going to jump head first into this considering the potential business advantages (most "carbon fiber" components out there are stickers or very cheap looking hydrographics). I've found some pretty slick deals on the kevlar 2x2 twill weave (commonly referred to as silver carbon fiber) as well as your typical 2x2 twill weave all black and colored/black carbon fiber cloth. I think with some patience and practice I'll be churning out legit wrapped parts in no time.

[chevy42083]

Fuel rail covers would be a nice start ;)
Semi easy shape/size, fit most of our cars.

[Fastbird]

Fuel rail covers would be a nice start ;)
Semi easy shape/size, fit most of our cars.

That's actually one of the first pieces I was thinking of doing. Actually I was going to experiment on our celica because right now we have a stick on kit in it (real red/black kev/cf though, not a sticker sticker) and I'd like to see it fully wrapped.

[stilltime]

A member on club3g.com does a lot of this, just started out of the blue. Seems pretty resourceful and has made a lot of different parts, namely interior pieces.

Give it a shot! I'll try and grab some pictures and tips from him.

[Fixxer99TA]

Do it up, Id buy em Fastbird :D

[Adam]

Here is some carbon candy for you

http://i384.photobucket.com/albums/oo286/adams95ta/DSC_0115.jpg
http://i384.photobucket.com/albums/oo286/adams95ta/DSC_0118.jpg

[Fastbird]

Guys, sorry I haven't updated this thread. I know some of you were patiently waiting for an update, and I apologize. Been working, and sick....but......ben churning out some stuff too. Most of it was for my Celica, but I am using that to get a technique down and it's coming along quite nicely. Contours are becoming a lot easier. Here's some examples of pieces I've been working on:

This C5 Vette door handle bezel was my first attempt at such a contoured piece. I'm VERY pleased with it. This picture is just the raw cloth adhered to the piece, no resin coating yet.
http://i72.photobucket.com/albums/i177/Fastbird93/Vette/1104081605b.jpg

This is with a couple coats of resin no sanding or finishing yet. You can see that I opened the weave by folding the cloth back on itself, my mistake, lesson learned.
http://i72.photobucket.com/albums/i177/Fastbird93/Vette/1104081605b.jpg

I've got 3 other handle bezels, so I'll probably save the "initial pieces" and do another set as they're going in my personal car.

The Celica stuff is red/black carbon/kevlar. This is my wife's envision for her baby, who am I to deny:

Ash tray cover:
http://i72.photobucket.com/albums/i177/Fastbird93/Celica/1104081605.jpg

Ignition Panel -- No Resin yet, little sketchy on the contour, but livable. The bottom in funky looking because there's a recess I intentionly left unadhered.
http://i72.photobucket.com/albums/i177/Fastbird93/Celica/1107081901.jpg
http://i72.photobucket.com/albums/i177/Fastbird93/Celica/1107081901a.jpg

Radio Trim -- No resin, initial stages, coming out VERY nice:
http://i72.photobucket.com/albums/i177/Fastbird93/Celica/1107081900.jpg
Edges wrapped:
http://i72.photobucket.com/albums/i177/Fastbird93/Celica/1107081956.jpg

Door Handle Bezels -- These were the most troublesome to date, and though they came out nice, it took some finagling. Finally figured out hte right compound for initial wet-out and adherence for the fabric to the plastic, and the second was MUCH easier than the first.
http://i72.photobucket.com/albums/i177/Fastbird93/Celica/1109081051.jpg
http://i72.photobucket.com/albums/i177/Fastbird93/Celica/1109081051a.jpg

I keep hitting the junkyards to try to get some F-body interior pieces (door handle bezels, switch plates, stereo trim, ect) but can't find any good pieces. I want to do a set of handle bezels for the F-Body really badly for some reason. Given the size and contour they shouldn't be too difficult.

My pricing is going to be EXTREMELY competitive. Preliminary pricing I'm only releasing for smaller pieces but here's what I'm thinking:

$75 for a pair of Firebird Door Handle Bezels
$50 for the door switch plates (both sides).

Those are all I've really thought about. My C5 handle bezels are going to be around $125 a set, I'm waiting on a set of C5 door handles and locks (the actual handle and locks, guy disassembled the entire assembly to get this done) that I'm doing for $75, and I'm also waiting for delivery of a C5 Blackwing Icebox that I'm doing for a gentleman for $125 (larger piece, more time involved even though the contouring will be a snap).

Now, if anyone want's to get something done, considering my fledgling status at this, I'd be willing to cut a steep discount to if you want to play guinea-pig. Just post up or shoot me a PM.

How's it looking so far? I'm going to be finishing up several of the above pieces this weekend, so more to come.

P.S. -- If pics and captions don't match up, I'm working on this post blind behind a firewall at work and can't see my own pics. Will edit tonight if somethings messed up.

[95LT1Z28]

I like the way the products are turning out. Look very good. I was wondering if you would consider doing a carbon fiber 2 or 3 pod pillar gauge mount. I think thatd be very nice.

[Fastbird]

Covering a aftermarket piece I'd try. I have zero intentions of actually fabricating something from scratch though.

[95LT1Z28]

Right, im saying maybe buy one of the autometer sets and send it to you to have it covered. Fabricating it would be very time consuming for how much you could actually sell them for.

[Fastbird]

Right, im saying maybe buy one of the autometer sets and send it to you to have it covered. Fabricating it would be very time consuming for how much you could actually sell them for.

That shouldn't be too bad to cover then. I actually have a VERY limited production (think approx 15 in the world) triple dash pod for our Celica that I'm considering doing too.

[bottledbird68]

Where do you find colored carbon fiber?
My fiance has been trying to talk me into trying the same thing on parts for her WRX only she wants pink carbon...
And how hard is it to adhere the matting? Could you do exterior pieces as well?

[Fastbird]

Where do you find colored carbon fiber?
My fiance has been trying to talk me into trying the same thing on parts for her WRX only she wants pink carbon...
And how hard is it to adhere the matting? Could you do exterior pieces as well?

Just search google for carbon fiber cloth. I will say that I have yet to see a pink carbon fiber or carbon/kevlar cloth. Your wife may be SOL on that one.

As for adhering, it's pretty easy depending on what's being done. 3M Spray adhesive works great on pieces without a bunch of contours. Instant adherence pretty much. Now if it's a heavily contoured piece that will take some work getting the cloth laid nicely, you can swap to a meduim life epoxy (15-25 minute) that will give you time to move the cloth around and get everything laid before it starts sticking.

For exterior panels.......I'd skip the hand process all together and go straight to vacuum forming.

[bottledbird68]

Ah ha! Found pink carbon fiber lol. But, if you were to just wrap exterior panels what issues would you run into? I know she wants to do her roof too so vaccum bagging wouldn't be an option there. Can you just stick it and resin up an area that large and still have it come out good?
If that works I'm not too worried about the trunk and hood, those should go easier.

[Fastbird]

Ah ha! Found pink carbon fiber lol. But, if you were to just wrap exterior panels what issues would you run into? I know she wants to do her roof too so vaccum bagging wouldn't be an option there. Can you just stick it and resin up an area that large and still have it come out good?
If that works I'm not too worried about the trunk and hood, those should go easier.

It's all going to depend in how smooth you can get the finish and how well you finish it.

[bottledbird68]

It's all going to depend in how smooth you can get the finish and how well you finish it.
Hmm, can you sand and buff the resin to get it smoother then bring the shine back or will that just make a mess?

[Fastbird]

Hmm, can you sand and buff the resin to get it smoother then bring the shine back or will that just make a mess?

Most common application is to sand then spray with clearcoat. Fully cured it's quite durable. I've been playing with a self leveling resin that REALLY dries to a beautiful finish, but is a little too soft (granted I'm curing at about 65* in my hosue).

[bottledbird68]

Ok, now I'm really interested. She wanted to do a carbon trunk/roof/hood but doesn't really like the look of regular carbon. That and the only roof overlays I can find for the wrx are over $800. But, if I can stick and resin it, then clear it, wetsand and buff it, that sounds like the way to go for me.
Then I can do the hood and trunk too, not doing it for weight savings, just cosmetics, so wrapping will work for me and should go far easier as I won't have to make a mold.

[Fastbird]

Tip. Get practice parts to try first.

[Fastbird]

Three pretty much finished pieces. The vent is still rough around the edges and I need to paint inside the fins, but the other two are essentially done.

http://i72.photobucket.com/albums/i177/Fastbird93/Celica/1119082057.jpg

http://i72.photobucket.com/albums/i177/Fastbird93/Celica/1119082058.jpg

http://i72.photobucket.com/albums/i177/Fastbird93/Celica/1119082058a.jpg

[Huff035]

So where did this ever go? I was thinking about changing up my interior. You still doing this? hydrographics were on my mind but everythings still up in the air.

[Fastbird]

I haven't messed with much of this recently. I have everything on the work table in the basement still, just haven't had a want/need to work on any of it.

[Huff035]

oh. I've never saw the hydrographics ones in person, do they really look that bad?

[Fastbird]

oh. I've never saw the hydrographics ones in person, do they really look that bad?

They can look decent, but side by side they don't compare at all.

[Phstratton]

Could you do engine bay pieces like this?

[Huff035]

They can hydrographic engine pieces, if i decide to do it i'm getting my ram air box and a set of corvette lt1 fuel rail covers done.

[Fastbird]

Could you do engine bay pieces like this?

You can, it's all piece dependent.

I will say that I have a GREAT little vacuum pump setup now that makes for much easier initial layup. I just have to perfect my finishing technique.

[Huff035]

You should perfect it so i can have the real thing. lol