April 26th, 2023 - Composite Meeting Notes

Official Seat Wet Layup

Objectives:

  • Finish official seat wet layup

  • Vacuum bag and let cure

Materials Used:

  • Epoxy Resin and Hardener

  • Sponge Brushes

  • Paper cups

  • Wooden Stirring Sticks

  • Copper sheets

  • Carbon Fiber Weave

  • Fancy Carbon Fiber Weave

  • Honey Wax Mold Release Agent

  • PPE: Respirators, Gloves, Full Body Covering

Summary:

1. First thing we did was prepare our materials. For this layup, we will be using 8 layers of carbon (6 inside layers are using loose weave carbon, 1st and 8th layers use tigher weave carbon). We will also be adding a copper layer for electrically grounding the seat as it is connected to the firewall.

2. To get the correct size for the carbon sheets, we cut out a template using plastic to get the approximate size needed for each of our layers. We then layered the carbon according to the template and cut generous amount of carbon.

Tip: Be very careful handling the carbon sheets as to not move the weaves since it would cause imperfections in the final layup.

3. After preparing the carbon sheets, we applied a final layer of Honey Wax on the mold for good measure.

4. We then prepared our resin (mix 180g of Resin with 60g of Hardener and stir with wooden stick until no white streaks are visible) and applied a very thin layer using foam brushes.

Tip: Because of the Honey Wax layers, the resin may pill or bubble on the surface of the mold. So instead of “painting” the resin on the mold, tap the brush to apply the resin in all areas of the mold.

5. To apply the first layer of carbon we started by lightly tapping the carbon onto the mold from the middle and carefully laying the rest of the carbon down and over the edges. Before tapping more resin on the top, we used the palm of our hands to press the carbon onto the entire mold. When all bumps and bubbles are gone, we started to apply more resin on the top.

6. After four layers of carbon are applied, it is time to make the conductive layer. For this layer, we placed four copper weaves into the middle of the seat layup. After they were pressed onto the seat, another layer of resin was brushed over the copper and we continued to add the rest of the carbon layers.

Tip: Listening to music while doing layups speeds up the process :D However, listening to New Jeans can be very dangerous as the song may not leave your head for a long time.

7. After four layers of carbon are applied, it is time to make the conductive layer. For this layer, we placed four copper weaves into the middle of the seat layup. After they were pressed onto the seat, another layer of resin was brushed over the copper and we continued to add the rest of the carbon layers.

8. After all eight layers were applied, it is time to prepare the seat for the vacuum bag. This is a very familiar process. It consists of pressing a layer of peel-ply onto the final layer of the seat and draping a sheet of a breather on top.

9. We then moved the seat to the back of Inventopia and placed the seat on top of a large sheet for the vacuum bag.