That is the coolest thing I've ever seen except this http://forums.somethingawful.com/showthread.php?threadid=1107178&perpage=40&pagenumber=1
Build your own Carbon/Kevlar DH Hardtail
- Thread starter Nately27
- Start date
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Wow very cool. Keep us postewd as it progesses for sure.
I have a friend who works at a speed shop, making carbon NASCAR parts. Maybe Ill see if he can bring home some scrap rolls. Looksn great. Keep us posted.
I have a friend who works at a speed shop, making carbon NASCAR parts. Maybe Ill see if he can bring home some scrap rolls. Looksn great. Keep us posted.
Holy mother of god.....thaflyinfatman said:
(from the link)
he just made it to the top of the list of people NOT to piss off...
at last check approaching 1,300,000 hits
this guy is global
this guy is global
wow that is really impressive for a first shot, with the paint it looks extra tight, looks production. 
After the surface finishing, why couldnt you put on a final tidy layer instead of the female mold hassle?
now i'm almost thinking of making a bolt-on CF front-end for my bike instead of that steel boat anchor...
After the surface finishing, why couldnt you put on a final tidy layer instead of the female mold hassle?now i'm almost thinking of making a bolt-on CF front-end for my bike instead of that steel boat anchor...
sweet a carbon front on all that beautifull cnc would be awesome!!
now if you could just anodize some of it purple!!!...(i mean black....really...)
now if you could just anodize some of it purple!!!...(i mean black....really...)
Might I suggest aircraft supply places as a source for carbon and other supplies. Aircraft Spruce and Wicks are the 2 that I use a lot.
You should really get yourself some solid modeling software. This would eliminate any design issues so you could get it perfect the first time. Solidworks is easy to get and easy to learn.
Overall, awesome results for being homebuilt. There is a website of a guy who built his own carbon recumbant. He's old and a weightweenie but he has good step by step instructions. I'll try and find a link.
You should really get yourself some solid modeling software. This would eliminate any design issues so you could get it perfect the first time. Solidworks is easy to get and easy to learn.
Overall, awesome results for being homebuilt. There is a website of a guy who built his own carbon recumbant. He's old and a weightweenie but he has good step by step instructions. I'll try and find a link.
ooops too late! But purple will mean its cool, right?allsk8sno said:
Yeah, i considered it. i was gettin more and more weight concious towards the end, so i decided to just paint it and forget the carbon finish, and i was gettin really anxious to ride itzedro said:wow that is really impressive for a first shot, with the paint it looks extra tight, looks production.
. It would work though, mayby someday ill go back and make it look really nice! Ive finished the modifications to the chainstay and they turned out real nice, ill post some pics when i get back on monday. Ive got unigraphics NX3 now, so yeah, hopefully this will be avoided next time. but at least carbon lends itself to modifications very well.
very...very good idea!!!zedro said:
i feel that i speak for the group when i say...
we want action shots!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
we want action shots!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
Actually, I am pretty sure that he is getting a significant increase in strength by molding over the foam (positive mold) due to the composite effect. If the foam has good compression stiffness, it should be adding a ton of strength. I am too tired to dig out my machine component design book to get the equations since I just got back from my first DH day of the year 
I finished up the modifications, and ill be priming it and building it up tonight, hence...ride tomorrow! Heres a pic of the chainstay, it aint the prettiest thing in the photo, but it looks better in person.
the foam can take up at least 25psi, i tested it that high in the vacuum bag, so it adds a lot of buckling resistance to the skin. which is the first place it'd fail as i see it.
the foam can take up at least 25psi, i tested it that high in the vacuum bag, so it adds a lot of buckling resistance to the skin. which is the first place it'd fail as i see it.
How did you see 25psi with a vacume bag when atmospheric pressure is only 14.7psi at sea level? Did you have positive air pressure outside the bag?Nately27 said:
My hero! 
awww u match your bike
darek is a madman
OOO OOOOOO thats me on the right in the llast pic....I KICK ASS......
haha go derek you rock.
-Jacob
haha go derek you rock.
-Jacob
home made carbonfiber rocks
here are a few pics of a (way too modest) mate of mine:
no dh or street rig, quality build nontheless:
dust caps are mounted and are much better, stronger than the originals? Pic will follow
Detail of his road bike: all hand made in the barn
here are a few pics of a (way too modest) mate of mine:
no dh or street rig, quality build nontheless:
dust caps are mounted and are much better, stronger than the originals? Pic will follow
Detail of his road bike: all hand made in the barn
i do a quick test b/f i do anything big like this on a new carbon bike.Nately27 said:i finally been able to put some serious hours on my bike. it manuals like a madman, so ive tryin to do a lot of that. Anyways, here are some action shots:
a long stair gap:
find a big ^ where both wheels are on each side. do some seroius bouncing to see if it will have a quick failure. it will put a huge load on your head tube a
might crack it. if not you are good to ride. don't be afraide to do this test.
on a new proto it might save your neck!
Wow man that is really cool, I never would never have even thought of making a carbon frame myself. Good work, looks sweet too.
Badfastard that bike is home made? That thing looks great, tell your buddy to start selling some frames!
nately, if you plan to build another frame you can call me up and i will help, i live in charlottesville and have thought about doing that myself, but do not have the resources. ive got some experience in autocad and inventer 5, due to taking engineering classes for the past two years a hs. so if you want/need a helper shoot me a pm. if not, no big deal its all good.
Daniel
Daniel
stairs?
that frame has undergone a number of revisions since last year and it is black now
yeah the black looks worse in pictures, but iv heared that it looks better inperson. i havent seen it for myself
I saw a good process for doing carbon frames a guy who was building a recumbent used, to get a nice finish on the outside without using a female mold, he layed up a couple of layers of weave on a two half male molds and let it cure, then he took it out and reinforced the inside parts and then glued the halves together
thanks for the interest guys. I started a second full suspension frame about a year ago, unfortunately its stalled at the moment due to grad school bein so busy. We've got some cool new cnc equipment too to try out on the frame which im really excited about! Ive been writing up about it here: octobercycles.blogspot.com although like I said, its in need of an update an update too. Im crossing my fingers next semester will be a little lighter.
Hey Nately27, is that really a full carbon gearbox bike on your blog?
Nicely done! Keep up the good work, you're getting close.
Tell us more about the transmission system.
Nicely done! Keep up the good work, you're getting close.
Tell us more about the transmission system.
You don't have to buy an expensive vaccum pump to vac bag your work, I made a vac pump out of a fridge compressor, vacuum advance from a car and a few pieces of plastic tube. Cost me about $12 and works fine. There are plans on the interweb for this type of thing.
I got my foam cut to profile at a sign writer, cost me about $40 and saves a lot of hassle shaping the core. A sign writer can use a DXF file, generate this file in CAD programs or illustrator all pretty easy stuff.
try to use unidiectional fibres in critical areas where you know the main direction of loading. EG you can run uni fibres along the top and bottom of the top tube then wind them around the head tube and back down the dt, this really locks everything inplace, and is more efficient use of carbon than just using it as " black aluminum".
I got my foam cut to profile at a sign writer, cost me about $40 and saves a lot of hassle shaping the core. A sign writer can use a DXF file, generate this file in CAD programs or illustrator all pretty easy stuff.
try to use unidiectional fibres in critical areas where you know the main direction of loading. EG you can run uni fibres along the top and bottom of the top tube then wind them around the head tube and back down the dt, this really locks everything inplace, and is more efficient use of carbon than just using it as " black aluminum".
Crap that's cool too! Carbon has taken over the world!
that gearbox bike is gonna be nasty
Metzy, what is the weight going to be on that frame? It is sick looking!!!! I know it is a gear box bike but how will the rear suspension work? Is it going to be a SP or floating? Great work man!!!
The frame is on track to weigh 7.5lbs including the shock. front tri is about 4.5lbs, rear 2lbs when finished, + bits and pieces. Is going to be a trail bike so should build up to a respectable weight.
The rear end is high single pivot. There is a lot of confusion about single versus multi pivot. With a high pivot you get some huge advantages as far as pedalling and bump eating geometry, this is all described with high school physics, its not confusing just blurred by lack of knowledge and the crap in magazines. Have a look at the lahar web site for some nice speil. As far as multi vs single pivot, not even worth discussing, they are not that different.
blah blah blah.
have a nice day
The rear end is high single pivot. There is a lot of confusion about single versus multi pivot. With a high pivot you get some huge advantages as far as pedalling and bump eating geometry, this is all described with high school physics, its not confusing just blurred by lack of knowledge and the crap in magazines. Have a look at the lahar web site for some nice speil. As far as multi vs single pivot, not even worth discussing, they are not that different.
blah blah blah.
have a nice day
Like pedal feedback and ultra-harsh feeling while trying to pedal through rough terrain caused by chain extention. Of course with a roller you can get around this, but the magazines and other people aren't lying to you, it's simply that most "high pivot" bikes make no provision for the extending chainline.