Crap, just realized I screwed up on the epoxy mixture. With this type of epoxy, you measure by weight. I added too little hardener, forgot to add the weight of the cup which was heavy due to previous epoxy mixtures. Stuff has not hardened; it’s going to be a mess to pull it apart. Stuck right now hoping it will eventually set. It's a .33 ratio. Oven hovers at 100 deg. I might need to add another light bulb.
Letting the cover stay in the oven for another day. Looks to be setting very slowly. I might have to redo this one.
In the meantime, I need to start on the other side cover. Since I won't be able to show the process while I'm working. I can at least show the order. The layup is one layer of Carbon fiber followed by 2 layers of fiberglass then a layer of Peel Ply. The Peel Ply is used to allow excess epoxy to be absorbed by a final layer of paper towels. You will end up using a few layers of paper towels to soak up the excess resin. Any extra epoxy only adds weight. All this is enclosed with a plastic bag and vacuumed. I use a Gast vacuum, they are meant to run continuously. You also need to make sure the vacuum tube does not get plugged during this process. I use a layer of cotton to surround the tube’s opening and have it stretched out to provide a path for the vacuum to work. The paper towels will also provide this as well. Shown is the wheel cutter I use to cut the materials. I find that is the best way to keep the weave from getting loose. Make sure you leave enough material to account for the walls. I do all this work in a home build vented hood. With positive airflow, I rarely smell the stuff since it vents to the outside. Also use gloves since long term use, you can develop an allergy to the epoxy. You don’t want these chemicals in your system.
You want to prep the work by having all the layer cut and in the order of placement. It's very messy to work with epoxy, and often time your hands will be pressing into the fabric. Last thing you want to do is try to cut the material with sticky gloves. I use a disposable brush to apply the epoxy. To get a good finish, your first layer is actually the epoxy brushed onto the mold. This will reduce any bubbles and avoid any dry spots. You then place the first layer, in my case carbon fiber. In the previous shell I use a layer of fiber glass that is finer than the next two layer to be placed. This shows up in the finish. Each layer is place carefully, to avoid opening up the loose weave. Once placed, I use the brush to soak the layers. Don't worry about the bottom not getting epoxy. The epoxy will soak itself into the fibers. You want to be more concerned with keeping the layers pressed into all the crevices. You aren't going to be brushing on the epoxy, the technique is called stipling. You basically are dabbing with the brush and using it to press the weave onto the mold. The weave will conform to most contours. Once all the glass layers have been place, you add the Peel Ply. The layer covers the others. You then do the same with the paper towels and then bag the whole setup.
Layers all cut up and ready to be placed.
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The stackup order is reversed so it easy to proceed.