Carbon Fiber Top Shell 22-24

Total time: 12 hours

• Started 8 PM and ended 8 AM

Materials used

• 4 ply carbon fiber
• 1 layer of Gurit foam core (find exact type)

Step-by-step guide

Mold-Prep

1. Sanded fiberglass mold to 400 grit with orbital sanders and used Bondo when needed
2. Applied 5(?) layers of wax
3. Applied __ layers of PVA sprayed with a paint gun

Layup

1. Applied 2 layers of carbon fiber and epoxy
2. Applied Gurit foam
3. Applied 2 more layers of carbon fiber and epoxy

Post-Processing

1. Demolded by sticking a metal ruler between all the edges of the fiberglass mold and carbon fiber mold and it was extremely easy to pry off after that. 
   1. Need someone pushing down while you push up
2. Peeled off PVA
3. Sanded to 320 grit with orbital sanders and used Bondo when needed
   1. Learned a neat trick from Tessa on electric; you can fill holes with resin and then put clear packing tape on it 
   2. Ended up using 80 grit orbital sanders on resin-patched spots and sanded through 2 layers of carbon fiber into the foam. Have to be more careful next time
4. Cut the lip off the composite with a dremel

Future reference & lessons learned

Related articles

• Page:
  (WIP) Composite Materials and Material Acquisition
• Page:
  (WIP) Composite Layups
• Page:
  Laser Cutting
• Page:
  Aeroshell Wet Layups for Dummies
• Page:
  (WIP) Canopy 22-24