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I'm making a frame for my daughter and the plan was to use carbon tubing bonded into aluminium lugs.
Problem is I'm struggling to find anywhere that does the right sizes in the right layup.
I was wondering if anyone here works in the industry and might be able to help?
I need 5 short pieces (3 x 35mm Ø and 2 x 20mm Ø) for the frame and was hoping someone may have some offcuts lying around..
Fun project. Hopefully there will be pics. 🙂
I'd make my own tubes, or more likely, make a foam structure incorporating the lugs then wrap the whole lot in fibre.
You need oliverracing, if memory serves, he's made a couple of carbon frames now
I wouldn't know where to start with making my own tubes unfortunately.
Easy composites do one size but not the other 🙁
They do close enough for both if you go to the rolled tubes.
I'd make my own tubes, or more likely, make a foam structure incorporating the lugs then wrap the whole lot in fibre.
The folks I know who've made CF frames have done it this way. (ref. Richie Goldsbury, Rob Metz).
As a student project (post grad masters but without the Masters) I built a rapidly deployable frame constructed using the same principle - I had some fancy hinges joined using CF tubes.
The good thing for me (and you) is that the ID of the tube is well controlled as that's what is wrapped on the mandrel.
Anyway, good luck and keep us informed with progress. I'm sure I'll fancy doing something similar in a few years!
They sent me a sample of roll and weave and the wrapped didn't feel anywhere near as strong/stiff as the woven.
Will have another look..maybe it was just a thinner section, can't remember what it was now 😳
I looked at this method when making some of my frames ([url= http://singletrackmag.com/forum/topic/homemade-carbon-xc-frame-pics-and-details-as-promised ]Frame No1[/url] [url= http://singletrackmag.com/forum/topic/carbon-full-suspension-frame-build-updates ]Frame No2[/url] [url= http://singletrackmag.com/forum/topic/carbon-frame-build-no3 ]Frame No3[/url]) but I think you'll struggle to get the right sizes without making your own tubes (quite easy and see my write-ups for guides or google it).
I agree with richmars (Who's also made carbon frames) your best bet would be to make a foam core and to do the carbon layup over that, see my frame No2 for how I did that, but make sure you have a good jig holding all the contact points (headtube, dropouts and BB) securely and in alignment.
My current research is looking into the feasibility of 3d printing sections of the internal plug, partly to add strength but to also allow for far thinner structures (foam tube get very flexy/brittle at less than 12mm diameter, which makes a ~16-18mm diameter carbon tube)
Plus 1 for the foam core, cold cure wrapped method. I'd say it takes a bit of practice to work out the best methods for what you want to do and what you feel comfortable with but it's a very versatile, if a little crude way of trying something, getting it wrong, tweaking it, trying again, hack sawing bits off, trying again, having it collapse on you whilst riding....fixing it, trying again....
It doesn't feel like it at times but it is fun - if a little sticky, dusty and messy. Honestly!
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andthe plan was to use carbon tubing bonded into aluminium lugs.
I wouldn't know where to start with making my own tubes unfortunately.
Don't really compute. Don't take this the wrong way but are you sure this is a good idea?
Don't really compute. Don't take this the wrong way but are you sure this is a good idea?
It's precisely the amount of knowledge I started with, if he does his research there's no reason why he could make something great! These days google is your friend, even 4 years ago there was only a fraction of the "how to" videos compared to whats online today.
Don't really compute. Don't take this the wrong way but are you sure this is a good idea?
I'm happy in my knowledge of bonding the tubes to the lugs but not in making my own tubes etc. I'm trying to leave that bit to the experts 😉
I'm happy in my knowledge of bonding the tubes to the lugs but not in making my own tubes etc. I'm trying to leave that bit to the experts
Having done my research, the most complex bit is the bonding, making the tubes requires a little bit of prep and a clean surface but easily doable for an amateur.
A good bond needs two properly prepared surfaces, proper adhesive that can cope with the different thermal expansion of the materials. And that's before you even consider trying to prevent galvanic corrosion of the aluminium under the bond!
Talk to Scott at Snapdragon Composites in Liphook.
He makes an obscene amount of high end stuff for the GTR's, P1's, etc and is always up for mad projects on the side - sure he'll have bits floating about.
I'm happy in my knowledge of bonding the tubes to the lugs but not in making my own tubes etc. I'm trying to leave that bit to the experts
That's cool then - I was a little worried that you had no knowledge at all .... just thinking about your daughter's safety!
I've done some [fairly ugly] boat spinnaker pole repairs (quite big at about 15-20cm diamater) and it's not too tricky. As has been said, prep is key and shrink tape is cool 🙂
Not sure I'd know where to start with bonding to aluminium though.
It's really not that hard.
I built my first carbon frame before there was as much info (and parts) available on line. It's a bit messy but you end up with something that will work. It just may not look that good.
In theory, you should separate the carbon from the aluminium with something non conductive (I used glass fibre) to prevent galvanic corrosion, but in practice I wouldn't bother.