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  1. M

    How long do composite molds last?

    Suppose I construct a plug, mold and create my desired part from this. I then want to store this plug and mold for future use in five or ten years for example. How long do composite molds last? How should a composite mold be stored? Can warpage be prevented?
  2. M

    Female mold from blown plastic to make symmetrical airfoil shape

    Could you use the blown plastic method to do the following? 1) Blow plastic shape based on the top profile which is based on an airfoil. 2) Layup fiberglass onto the outside of the plastic to create a female mold. 3) Construct top/bottom fairings using the female mold. 4) Blow accurate...
  3. M

    Flexible strip hot wire cutting guide

    I am looking for examples of the use of a flexible guide for hot wire cutting rather than trying to trace a sharpie line. Something like using a couple rods of fiberglass that can produce a consistent bend and be pinned into place. Once the guide is in place the hot wire can run along the...
  4. M

    How big of a gap trips boundary layer?

    I have read that turbulent air can have double to drag. Tripping the boundary layer is a not good. How big of a gap in-between panels for example trips the boundary layer?
  5. M

    Recumbent Streamliner Build Thread

    Hello, it appears some people are interested in my project which is good to hear so I have made this thread to get as much help as I can. I have 10 weeks until I will be busy, this means I have 10 weeks to build a fully operational streamlined bicycle. What in 10 weeks? 1) A recumbent...
  6. M

    How to extrapolate the curve that connects airfoil coordinates for aerodynamic shape carved into foam by hand without CAD?

    Hello I want to carve an aerodynamic shape based on horizontal and vertical airfoil coordinates and a single cross section to ensure fit then extrapolating to every airfoil coordinate along the body. How can I extrapolate this curve? I have seen the Arnold Company videos where he uses...
  7. M

    Foam core composite motorcycle top box surface finishing advice please

    This is my first foam core composite project. An aerodynamic motorcycle top box and this is where I am up to. The foam layers were hot wire cut, stacked glued together and sanded to shape. I used some pastor stuff to fill low spots but I should not have. I then put layers of fiberglass on...
  8. M

    Plastic layers between foam ribs and carbon for removing foam for extra lightness

    I just came up with an idea for removing the foam ribs in a composite mold for increased lightness. Step 1) Layup 1. Carbon fiber(s) layer (vacuum bag). 2) Plastic layer. 3) Foam rib, clay, whatever needed to get the desired shape. 4) Plastic layer. 5) Layup 2. Carbon fiber(s) layer (vacuum...
  9. M

    Core materials for resin infusion with best strength to weight ratio for use with compound curves

    I am looking to build an extremely aerodynamic light weight velomobile fairing with compound curves. I can't use Nomex Honeycomb since the holes will fill up with resin. Searching has not revealed the best possible appropriate resin infusion core material so I have to ask. Ideally a material...
  10. M

    Steel or wood for fabric covered motorcycle full fairing.

    I am considering wood strips 25mm x 4mm or steel flat 10mm x 3mm bar for a frame to be covered by Dacron before painting. I am considering a front and rear section with or without side doors. The frame is to be constructed while mounted to the motorcycle to ensure adequate clearances. It is...
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