Since I wanted something like a Scotty Gauge pod for my race truck, I decided to make a pod like his out of carbon fiber. Keep in mind that I've never worked with either carbon fiber or fiberglass, I think its coming along nicely. Mine is a bit longer I need switches and 4 visible gauges. Thinking that someone may enjoy following along, here's the process:

Planning.
I visited several sites, including http://www.sheldonbrown.com/rinard/carbon_fiber.htm which is ironic since I abhor bicyclists who don't share the road with me. I ended up ordering the epoxy resin, carbon cloth and misc stuff from US Composites. ( http://www.shopmaninc.com/ )

The Mold.
Making the mold seemed fairly easy. It was made from 2" PVC pipe and 1/2" foam core insulation. The gauges are spaced 2 per side. The gauge layout from left to right is pyro, boost, switches, tranny temp and a pressure gauge.
first gauge:

cutting number 2:

1-4 fit:

foam was added in between the pipes:

aluminum foil and masking taped:


Fiberglass Underlay
Since the pod has to be built up before laying the carbon fiber, a combination of fiberglass and bondo was used.

first layer of fiberglass:

the bondo before it was sanded:

tonight I layed 3 more layers of 4oz. cloth:


I'll post more when I get them finished. The test sheet of finished carbon fiber is done and I hope it's not to 'ricer' when finished. The full set of consecutive pictures is located in my signature.

brandon.

 

Looks good. Fiberglass is pretty easy to work with once you figure out how to do it. I've never played with carbon fiber though. I thought you had to put it in a vaccuum and heat it up real hot to make it cure? Maybe that's just how they make the parts for lamborghinis. Let us know how it turns out.

 

You don't have to put it in a vacuum, just an oven to "bake" it. This also depends on the resin you use.

 

Can't wait to see the end result, should look really good. Are you doing the carbon fiber yourself?

 

Ahh. Cool. Hmmm. Now your giving me ideas.

 

Putting it into a vacuum will make alot stronger and better looking part because its hard to get rid of the air pockets without the vacuum. We made custom snowmobile hoods out of carbon fiber. Some were vacuum formed and others were not and you can't believe the difference in quality.

 

The difference in quality from vacuum formed and not vacuum forming is unbelievable.

Here is my experience with carbon fiber... I still have about 16 square feet left sitting in my freezer.

Might try and make some more carbon fiber beer holders

http://turbodieselregistry.com/forum...t=carbon+fiber


Justin

 

That sure looks familiar.

 

Good idea. Maybe you should start selling them.

 

I should hope so! "I wanted something like a Scotty Gauge pod for my race truck..." "except longer" To tell the truth, I've been waiting for the Scotty Pods to appear in the DTR store for awhile now and decided I needed something else to do while I wait for my money tree to grow. And I needed an excuse for using carbon fiber. I also decided that it wouldn't be prudent to make a mold.

brandon.

 

Brandon, great stuff. Id like a longer one too...Are ya gonna make me one??

Looking forward to seeing the results.

 

Looks like fun Justin! Briefly considered pre-preg until current polls indicated I don't have a freezer so I had to go with just cloth/epoxy. The test CF piece showed that I'll need to make sure to wet out the carbon fiber completely. Plus, this stuff is EXPENSIVE! I'd LOVE to make a CF front clip for the '98, but I can't see that happening without $$$.

brandon.

(and no, I can't make anyone one. I fear my 180lb frame would snap like a twig when a certain northern neighbor found out )

 

You weigh 180lbs??? You look more "twig like" than that too me...maybe I'm just used to people like me and that northern neighbor.

Chris

 

Naaaha, hes a ***** cat....throw him a steak or three and he'll be fine...

 

Um,
Never mind

~Rob