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VIDEO TUTORIAL

USED IN THIS PROJECT

Although not necessarily an exhaustive list, the following tools and materials, supplied by Easy Composites, were used in this project.

The quantity shown below is the approximate amount used in the project rounded up to the nearest available kit size or quantity.

MATERIALS & CONSUMABLES
Resin Infusion Starter Kit Thumbnail
SK-RIResin Infusion Starter Kit£145.00 /kit

Medium Mixing Cup / Catch-Pot Liner Thumbnail
CPLINERSMedium Mixing Cup / Catch-Pot Liner£0.20 /each

6mm ID Budget PVC Vacuum Hose 5m Thumbnail
VH-PVC6-56mm ID Budget PVC Vacuum Hose 5m£5.95 /pack

ST150 Vacuum Bagging Sealant Tape 15m Each Thumbnail
VBST150ST150 Vacuum Bagging Sealant Tape 15m Each£4.99 /roll

VB160 Vacuum Bagging Film LFT (1520mm) 5m Folded Pack Thumbnail
AFVB160-152LFT-5PKVB160 Vacuum Bagging Film LFT (1520mm) 5m Folded Pack£12.40 /pack

Resin Infusion Spiral Medium Flow 10m Coil Thumbnail
RISP-M-10Resin Infusion Spiral Medium Flow 10m Coil£3.50 /pack

FM100 Infusion Mesh (1050mm) 5m Folded Pack Thumbnail
AFFM100-105-5PKFM100 Infusion Mesh (1050mm) 5m Folded Pack£12.00 /pack

PP180 Economy Peel Ply Black Tracer (1520mm) 5m Folded Pack Thumbnail
AFPP180-152-5PKPP180 Economy Peel Ply Black Tracer (1520mm) 5m Folded Pack£10.00 /pack

IN2 Epoxy Infusion Resin SLOW 5kg Kit Thumbnail
EP-IN2-S-5IN2 Epoxy Infusion Resin SLOW 5kg Kit£60.43 /kit

240g Carbon Fibre Narrow Fabric Plain Weave (50mm) Thumbnail
CF-TP-50240g Carbon Fibre Narrow Fabric Plain Weave (50mm)£2.41 /linear metre

Lantor Soric SF Infusion Core (1270mm) T=2mm Thumbnail
SORIC2Lantor Soric SF Infusion Core (1270mm) T=2mm£8.45 /linear metre

210g 2x2 Twill 3k Carbon Fibre Cloth (1250mm) Thumbnail
CF-22-210-125210g 2x2 Twill 3k Carbon Fibre Cloth (1250mm)£27.00 /linear metre

CR1 Easy-Lease Chemical Release Agent 500ml Thumbnail
CR1-05CR1 Easy-Lease Chemical Release Agent 500ml£16.50 /pack

Total £0.00
TOOLS & EQUIPMENT
Professional 10 Inch Carbon Fibre Composites Shears Thumbnail
SC-CK10Professional 10 Inch Carbon Fibre Composites Shears£40.95 /each

Resin Infusion Line Clamp Thumbnail
RI-LCResin Infusion Line Clamp£4.50 /each

EC.4 Compact Composites Vacuum Pump + UK Lead Thumbnail
VP-EC4-UKEC.4 Compact Composites Vacuum Pump + UK Lead£230.00 /each

CP1 Resin Infusion Catch-Pot 1.2L Thumbnail
RICP-P-SCP1 Resin Infusion Catch-Pot 1.2L£79.95 /each

Resin Infusion Silicone Connector Thumbnail
RI-SCVResin Infusion Silicone Connector£3.25 /each

10kg High Capacity Digital Scales Thumbnail
SCALE10KG10kg High Capacity Digital Scales£11.63 /each

Total £0.00

VIDEO TUTORIAL

How to Resin Infuse a Carbon Fibre Bonnet (or Similar Panel)

In part 2 we make the inner and outer skins for the bonnet using resin infusion of carbon fibre and Lantor Soric core material.


TUTORIAL BREAKDOWN

Spraying the GC50 epoxy compatible gelcoat (optional)

Spraying the GC50 epoxy compatible gelcoat (optional)

Before you can spray the gelcoat, the mould needs to be treated with EasyLease in accordance with the product instructions.

For many panels, a clear gelcoat is not necessary as the resin infusion already gives a great high gloss finish as standard. However we wanted to demonstrate this additional step for those that want the ultimate in high quality finish and UV protection without any post production finishing.

The GC50 is measured out and catalysed with MEKP before thoroughly mixing and loading into the G100 Gelcoat cup gun. Once appropriate PPE is donned, the gelcoat is sprayed onto the mould surface in an even layer before being allowed to cure.

Prior to beginning any of the lay up for infusion, the overspray is cleaned off the mould flanges and any drips or blemishes on the gelcoat surface are sanded out.

Laying up the fabric for the bonnet skin

2. Laying up the fabric for the bonnet skin

While the flanges are now clean, the Gum Tape is applied all the way around the flange. This is to ensure there are no stray fibres which could get trapped under the tape causing a small leak in the bag.

After carefully measuring the mould, the correct size piece of carbon is selected and laid carefully into the mould. The surface layer is a 210gsm twill woven carbon cloth. Extra care is taken to avoid distorting or pulling the fabric as this will be the visible layer on the top surface of the finished part.

The Soric core material is then cut to size leaving a small gap around the edge and placed in the mould. The gap is filled with several layers of carbon fibre tape so that there is not a ridge or noticable edge that could print through onto the surface. The fabric layup is then completed with another layer of the 210gsm twill Carbon Fibre.

Resin infusing the bonnet skin

3. Resin infusing the bonnet skin

The infusion stack is now added to the mould, starting with the peel ply, then mesh, silicone connectors, spiral and finally the vacuum bag. The infusion for this skin is an entirely conventional infusion process.

A vacuum is pulled on the bag and as is key with all infusions, a good leak test is conducted to ensure that the bag is air tight and all leaks have been fixed. Only at that stage can you consider doing the actual infusion.

The IN2 Infusion epoxy is measured out accurately on the scales and then thoroughly mixed. Once mixed, the pump is turned on and the infusion is commenced. Once the infusion is complete, the vacuum port and then the resin feed are clamped off and the pump switched off. The part can then be left to fully cure.

Once cured, the vacuum bag and bagging stack can be carefully removed. The peel ply can be ripped off in strips. Once done, carefully prise between the carbon and the mould surface to lift the edge and demould the part.

Resin infusing the inner frame

4. Resin infusing the inner frame

The basic infusion process for the inner frame is almost identical. The only difference is the layup is simplified to 1 layer of 210gsm twill cloth on the surface and 1 layer of 650gsm cloth backing. Some additional fabric is added to the hinge and hook areas for additional strength.

The same infusion bagging stack is done as before and following the leak test, the infusion is carried out. Once cured, the part is demoulded in exactly the same fashion.


DISCUSSION (7)

Please share any questions or comments you may have about this video tutorial.


Clay Newton
What is the purpose of the pleats in the vacuum bag sealant tape?
Easy CompositesMatt
The purpose is to ensure there is enough bagging film to lay into the details of the mould without the film going too tight and lifting from the surface.

James Eardley
What is the percentage of epoxy per square meter of carbon fiber?
Easy CompositesMatt
It sounds like you're asking about fibre fraction which is a ratio of resin weight to fibre weight (knowing only the resin per sqm etc.. isn't the full picture because you would need to know what weight and number of layers of carbon fibre were in that square metre). So, in terms of fibre fraction, resin infusion yields a laminate with 60-40 fibre to resin, so, 40% of the weight of the laminate is epoxy.

David Heath
Just wondering why you need to add the pleats to the bagging film? Is it to aid in the vacuum process?
Easy CompositesMatt
The pleats are there to ensure you have enough bagging film so that when it is pulled under vacuum it has enough film to avoid bridging of the film on the part.

joseluis aravelo
Why is there no infusion soric in-between the underside's two reinforcement layers but in the outer there is?
Easy CompositesMatt
The lower frame of the hood does not need the extra stiffness that the Soric core would add so it is left out.

Tiršti Dūmai
Could a bonnet like this, made using the IN2 Infusion Epoxy, and if it was, would it be able to take the temperature of hot sun?
Easy CompositesMatt
Yes, in our experience body panels (such as a bonnet) made by resin infusion using IN2 infusion resin are able to withstand the temperatures of hot sun however it is important to 'post cure' the component at elevated temperature, ideally in the mould, in order to fully cure the resin and achieve its maximum 'Tg' (maximum use temperature). Please see the IN2 datasheet for full details on post curing.

Bradley Wagman
Could you use the OEM hood as mold for the carbon fiber hood instead of making a whole other mold before you make the carbon fiber hood ?
Easy CompositesMatt
Well, not really. One significant problem with that method would be that the carbon part will end up slightly larger than the original part you used as a male mould. Another problem is that the part you take off it will have a perfect finish on the inside but would take many hours of sanding and polishing to get a reasonable finish on the exposed face (the side you see). Of course, you could skin the original hood and adhere carbon directly to the OEM part but this would be done purely for aesthetics and not to make a structural carbon part.

0lone0wolf0
So is there a reason u put the reinforcement on top of the two layers instead of in between them? I think it'll be cosmetically nicer that way. Thanks
Easy CompositesMatt
Do you mean the core material (Soric)? this has to be used within the laminate stack not on top of because the laminate needs to be balanced and thus whatever materials are on one side of the core need to be mirrored exactly on the other side; this is done to ensure that the two skins of the sandwich laminate work in unison with one another. Putting the Carbon Fibre Reinforcement on only one side would lead to warping and imbalance in the mechanical properties.

LEAVE A COMMENT OR QUESTION

Note: Your name will be abbreviated and your email address will only be used to email you the answer directly

USED IN THIS PROJECT

Although not necessarily an exhaustive list, the following tools and materials, supplied by Easy Composites, were used in this project.

The quantity shown below is the approximate amount used in the project rounded up to the nearest available kit size or quantity.

MATERIALS & CONSUMABLES
Resin Infusion Starter Kit Thumbnail
SK-RIResin Infusion Starter Kit£145.00 /kit

Medium Mixing Cup / Catch-Pot Liner Thumbnail
CPLINERSMedium Mixing Cup / Catch-Pot Liner£0.20 /each

6mm ID Budget PVC Vacuum Hose 5m Thumbnail
VH-PVC6-56mm ID Budget PVC Vacuum Hose 5m£5.95 /pack

ST150 Vacuum Bagging Sealant Tape 15m Each Thumbnail
VBST150ST150 Vacuum Bagging Sealant Tape 15m Each£4.99 /roll

VB160 Vacuum Bagging Film LFT (1520mm) 5m Folded Pack Thumbnail
AFVB160-152LFT-5PKVB160 Vacuum Bagging Film LFT (1520mm) 5m Folded Pack£12.40 /pack

Resin Infusion Spiral Medium Flow 10m Coil Thumbnail
RISP-M-10Resin Infusion Spiral Medium Flow 10m Coil£3.50 /pack

FM100 Infusion Mesh (1050mm) 5m Folded Pack Thumbnail
AFFM100-105-5PKFM100 Infusion Mesh (1050mm) 5m Folded Pack£12.00 /pack

PP180 Economy Peel Ply Black Tracer (1520mm) 5m Folded Pack Thumbnail
AFPP180-152-5PKPP180 Economy Peel Ply Black Tracer (1520mm) 5m Folded Pack£10.00 /pack

IN2 Epoxy Infusion Resin SLOW 5kg Kit Thumbnail
EP-IN2-S-5IN2 Epoxy Infusion Resin SLOW 5kg Kit£60.43 /kit

240g Carbon Fibre Narrow Fabric Plain Weave (50mm) Thumbnail
CF-TP-50240g Carbon Fibre Narrow Fabric Plain Weave (50mm)£2.41 /linear metre

Lantor Soric SF Infusion Core (1270mm) T=2mm Thumbnail
SORIC2Lantor Soric SF Infusion Core (1270mm) T=2mm£8.45 /linear metre

210g 2x2 Twill 3k Carbon Fibre Cloth (1250mm) Thumbnail
CF-22-210-125210g 2x2 Twill 3k Carbon Fibre Cloth (1250mm)£27.00 /linear metre

CR1 Easy-Lease Chemical Release Agent 500ml Thumbnail
CR1-05CR1 Easy-Lease Chemical Release Agent 500ml£16.50 /pack

Total £0.00
TOOLS & EQUIPMENT
Professional 10 Inch Carbon Fibre Composites Shears Thumbnail
SC-CK10Professional 10 Inch Carbon Fibre Composites Shears£40.95 /each

Resin Infusion Line Clamp Thumbnail
RI-LCResin Infusion Line Clamp£4.50 /each

EC.4 Compact Composites Vacuum Pump + UK Lead Thumbnail
VP-EC4-UKEC.4 Compact Composites Vacuum Pump + UK Lead£230.00 /each

CP1 Resin Infusion Catch-Pot 1.2L Thumbnail
RICP-P-SCP1 Resin Infusion Catch-Pot 1.2L£79.95 /each

Resin Infusion Silicone Connector Thumbnail
RI-SCVResin Infusion Silicone Connector£3.25 /each

10kg High Capacity Digital Scales Thumbnail
SCALE10KG10kg High Capacity Digital Scales£11.63 /each

Total £0.00

DISCUSSION (7)

Please share any questions or comments you may have about this video tutorial.


Clay Newton
What is the purpose of the pleats in the vacuum bag sealant tape?
Easy CompositesMatt
The purpose is to ensure there is enough bagging film to lay into the details of the mould without the film going too tight and lifting from the surface.

James Eardley
What is the percentage of epoxy per square meter of carbon fiber?
Easy CompositesMatt
It sounds like you're asking about fibre fraction which is a ratio of resin weight to fibre weight (knowing only the resin per sqm etc.. isn't the full picture because you would need to know what weight and number of layers of carbon fibre were in that square metre). So, in terms of fibre fraction, resin infusion yields a laminate with 60-40 fibre to resin, so, 40% of the weight of the laminate is epoxy.

David Heath
Just wondering why you need to add the pleats to the bagging film? Is it to aid in the vacuum process?
Easy CompositesMatt
The pleats are there to ensure you have enough bagging film so that when it is pulled under vacuum it has enough film to avoid bridging of the film on the part.

joseluis aravelo
Why is there no infusion soric in-between the underside's two reinforcement layers but in the outer there is?
Easy CompositesMatt
The lower frame of the hood does not need the extra stiffness that the Soric core would add so it is left out.

Tiršti Dūmai
Could a bonnet like this, made using the IN2 Infusion Epoxy, and if it was, would it be able to take the temperature of hot sun?
Easy CompositesMatt
Yes, in our experience body panels (such as a bonnet) made by resin infusion using IN2 infusion resin are able to withstand the temperatures of hot sun however it is important to 'post cure' the component at elevated temperature, ideally in the mould, in order to fully cure the resin and achieve its maximum 'Tg' (maximum use temperature). Please see the IN2 datasheet for full details on post curing.

Bradley Wagman
Could you use the OEM hood as mold for the carbon fiber hood instead of making a whole other mold before you make the carbon fiber hood ?
Easy CompositesMatt
Well, not really. One significant problem with that method would be that the carbon part will end up slightly larger than the original part you used as a male mould. Another problem is that the part you take off it will have a perfect finish on the inside but would take many hours of sanding and polishing to get a reasonable finish on the exposed face (the side you see). Of course, you could skin the original hood and adhere carbon directly to the OEM part but this would be done purely for aesthetics and not to make a structural carbon part.

0lone0wolf0
So is there a reason u put the reinforcement on top of the two layers instead of in between them? I think it'll be cosmetically nicer that way. Thanks
Easy CompositesMatt
Do you mean the core material (Soric)? this has to be used within the laminate stack not on top of because the laminate needs to be balanced and thus whatever materials are on one side of the core need to be mirrored exactly on the other side; this is done to ensure that the two skins of the sandwich laminate work in unison with one another. Putting the Carbon Fibre Reinforcement on only one side would lead to warping and imbalance in the mechanical properties.

LEAVE A COMMENT OR QUESTION

Note: Your name will be abbreviated and your email address will only be used to email you the answer directly

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