Chapter 9 Carbon Fiber Bike Build.wmv

[allthevideosilike]

you made it look easy

[TheProjectJunkie1]

@allthevideosilike

Honestly, it wasn't that hard of a project except for the fact that it was a lot more time consuming than I thought it was going to be. Sticking with it through problems and enduring to the end are the keys to successfully building your own bike. Thanks for the comment.

[nickssanity]

the bike looks awesome for a first build, i'm really interested in trying to build my own, my main problem is - i have no idea where to get the carbon fiber cloth. where do you get yours?

[TheProjectJunkie1]

@nickssanity

If you live in the US, Canada, or Europe, getting your hands on some carbon fiber isn't going to be a problem just do a search for it online and you'll have a ton of options to choose from. I get my carbon fiber from a variety of suppliers like CJ Composites, Fiber Glass Supply, James Town, and etc. I don't really have a favorite, it just depends on who's got what I need for the best price.

Let me know when you get started on your build- I'd love to follow it.

[circusboy90210]

@TheProjectJunkie1 please let me know if you are interested in carbon nanotube technology or metal honeycomb sandwich carbon fiber/ or carbon nanotube . dreaming of doing an aviation project thanx for your video.

[TheProjectJunkie1]

@circusboy90210

I'm very interested in nanotube technology but I don't know that much about it. I've never used the metal honeycombs because most of my stuff is wet-layup or wet-prepreged. An aviation project is a great idea. I have a Quickie Q200 kitplane that is currently on hold- pending funds :-( I'm anxious to get back to it but for now I'll do these smaller projects. This plane is where I started learning about composites- so a lot of good can come from getting into airplanes.

[circusboy90210]

@TheProjectJunkie1 my dream is a bd-5j have access to molds and would love to do what you did but with that little plane it's 12' front to back and 12' wing span would like to go with 2' more wing to support a slightly larger engine. only would like to involve composite honeycomb construction for additional stiffness and strength at this level weight is negligible.

[TheProjectJunkie1]

@circusboy90210

I love the bd-5j. I didn't know they were making out of composites now- That's awesome. I knew a guy when I was a kid that was building one of the prop versions. I don't know if he ever finished it. There's a guy in my local EAA chapter who's dad built one- tragically his dad die in it after a fatal crash.

[circusboy90210]

@TheProjectJunkie1 jim bede stopped making the plane a long time ago. I have access to fiberglass forms for this plane outer banks of NC working with carbon fiber is so similar I want to go for it. nobody builds these planes much. the problem with these planes is pilot error . will be installing a plane chute on the unit for sure. glass cockpit gps etc... fly by wire.

[TheProjectJunkie1]

@circusboy90210

Amen on the cute. I promised my family I'd put a plane shoot on mine before flying it. Expensive but they seem to work good from what I've researched. What kind of glass you thinking about? I currently like the EFIS Light by Blue Mountain but who knows what will be out by the time I'm done with my plane.

[circusboy90210]

@TheProjectJunkie1 off the shelf garmin unit.

[miscriant]

Do you do any track? you should try to make a carbon fiber track frame would be nice

[TheProjectJunkie1]

@miscriant

Track looks fun but it's not convenient around here where I live. So, with that said, if I ever got into track cycling I would probably try making my own frame for it- If there aren't strict regulations against home-built bikes.

[jonmuers]

well done dude, you should be proud!!!!

[NathanTouring]

Bravo! Nice work there on such an ambitious project..

[TheProjectJunkie1]

@brandon2012a

LOL I normally love dogs, but absolutely hate them while riding my bike, or running for that matter. It's funny you mention this- a couple of months ago my friend almost died after hitting a cat that ran across the road. He wiped out bad- luckily he was wearing his helmet which is now in pieces and aside from some major road rash and bruising he was ok. This project was a great learning experience. The new frame I did is much sexier. You can see it on my channel- it's the Z-Frame.

[TheProjectJunkie1]

The frame only, was about $160 in materials.

[olivalondon]

Nice! How much did u spend, all together

[rpjstan]

no offence cos this is a cool project and all that,

but it looks ugly as sin from what i've seen on of the frame

[TheProjectJunkie1]

@rpjstan

I'm not offended because I agree. But what you plan on and what you get sometimes isn't always the same thing- especially, the first time around.- People that have taken on frame builds know what I am talking about.

I'll be the first to admit that I don't like the amber/carbon finish- It looks like a carp (fish). I also don't like the seat tube clamp, and the headtube to fork transitions turned out lousy. Though she's not beautiful, I like the way she rides;-)

[davism4a1]

have u done a laminate steel/carbon fiber knife? or at least thought of it?

[TheProjectJunkie1]

LOL, I wouldn't trust any bike going 50mph+ down a mountain road. In fact last week my good friend lost a bother-in-law while bombing a hill- Pretty sad. Anyway, I start breaking around 40mph and that's if the road is smooth and straight. As far as integrity goes I've got over 1,500 miles on the frame now with no serious problems yet. I've been 35 mph over train tracks no problems and almost endo'd over a storm drain. Still going strong, but I'll be retiring this frame for a new homebuilt soon.

[WhiteGravey]

would you trust this bike going 50mph+ down a mountain road?

[TheProjectJunkie1]

Feel free to ask me anything you need- I don't get bothered by questions. I lost the video on the tube cutting process but it was done with templates and a homemade hotwire cutter. I did some touch-up sanding on the Styrofoam if needed. You could sand it uniformly with templates and a long sanding block or by making a long sanding block with the negative profile you want. I've seen it done on urethane foam for a hydrofoil. If you need more info on the process PM me and I'll see if I can find it.

[TheProjectJunkie1]

I'm in the middle of a new frame build so stay tuned. It looks a lot like the Lotus Sport Bike Frame. I'll be posting some videos soon.

[TheProjectJunkie1]

The cost was just for the frame. I got my carbon fiber from CJ Composites- I used about 2 yrds of 6k, 11oz, 5 harness satin weave carbon fiber. I believe it was AS4, so standard modulus. I used EZ Poxy 83- because I had some but recommend West Systems 105 or recently I've been using Resin Research's Project 21 system (slow) on some longboards with good results. It's much cheaper with good curing properties. I used about 1/2 gallon of resin on my frame. Layup schedule is on my website. Have Fun!

[shorguy322]

@TheProjectJunkie1 last question. How did you shape the styrofoam into the airfoil shape exactly? Sanding doesn't seem to work because it's not a uniform sand (some places are sanded further than others), and I'm experienced with working around sandpaper/resins/fiberglass. did you use a hot wire cutter? Thanks

[stefanisgiannis]

Very very very goooooood job ...... keep going man.

[shorguy322]

Just wondering, you said it cost around $169 plus some change. where did you get the fiber from, what grade is it (3k, 6k, 12k, ect.) and the resin? Thanks a lot