I´m forwarding Sam´s mail, because strangewise it arrived uuencoded to the list:
Are you using the PU to make a sandwich construction?
I'm going to build a foam-core frame, which means that the carbon is draped over the foam and the foam is kept in place. I don't know whether it is called a sandwich construction when not a straight plate - but the idea is the same, yeah :)
When moulding the bike – will you use more than one layer of carbon fibre?
The amount of layers depends on the type of carbon used and the stress on a point (which you have to estimate). I mailed Jim Scozzafava ( www.jjscozzi.com ) about how much he used, and he said that he aimed for .06-.07" (1.7mm) in general and up to .1" (2.5mm) for high stress points. Since I will be using 200g/m2 twill carbon that dresses out to approximately .3mm, I'll be using something like 5 layers in general (the foam adds some strength, and I want to go off-road with the bike, so I still need to find out whether that is sufficient for a mtb-like bike as well, but as a guideline I like it). On high-stress points I will either use UD-tape when forces are mainly in one line, or 410g/m2 carbon for extra strength.
Times when I think of carbon fibre python I think of a front part where the fender/mudguard is an integrated part – would that be possible you think?
I guess so - but you would need to find a way to service all the parts that are inside and the chain needs to go through the mudguard. Maybe a removable (but carbon) mudguard that fits nicely into your frame would work better.
You have to use solvent with epoxi?
Yeah, to clean the tools :) So that's definitely the part I like least, but hell - who likes cleaning up? ;)
Looking forward to your blog!
Still working on it :)
This is the Python Mailinglist at freelists.org
Listmaster: Juergen Mages jmages@xxxxxx