I'm gathering the necessary equipment to start my next little hobby project building my own fairings. I got about 5 yards of carbon-fiber/Kevlar and another 5 yards of fiberglass, 10ft of 3' carbon fiber "tape", a gallon of epoxy, a quart of pva release, a vacuum pump, degassing chamber, and all the plastic and tape to do vacuum bagging.
I'm hoping to minimize the amount of trial and error due to the expense of the carbon fiber. I've done a lot of reading and a little bit of YouTube watching as well. I want to open up this question to see if anyone might have some worthwhile knowledge to impart. It's appreciated.
My big open questions at the moment are, how many layers should I build up and will I need a filler material (honeycomb or poor mans alternative: cardboard). Currently I'm planning to do a layer of the more expensive black and red carbonfiber/Kevlar hybrid on top, with a couple layers of slightly cheaper carbonfiber on the backside, and a layer or two of fiberglass sandwiched in between.
Also, it's not really clear to me what should be done when you have to build the part in multiple pieces? Due toll the curves and mounting points on the back I think I'll have tonsils the front and back as separate parts, and in some cases to account for angles may have to build a piece in 3 or 4 parts. My question is, how do you then bind those parts together to assemble the final result? This seems like a stupid question that will undoubtedly end with a smack on the forehead.
I'm planning to start with either the upper side fairings (the bottom two "wing" looking pieces in the picture) or the airbox cover (top right), followed by the rear underbody (top left in picture), lower sides (not shown but in second picture, they are the large pieces on the right bottom), upper rear (second row on left in picture), and end with the front pieces (second row on right and 3rd row on left) which I imagine will be the most challenging.
To me it's all fun, whether I screw up or or. I enjoy the process. It'll be a lot more fun if it turns out well.