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I think I should start with a disclaimer: I have been playing with DIY carbon fiber wrapping for a couple years and never really managed anything impressive. Now that I have a Vette, I decided to take my time and be a bit more serious with it. I plan on doing my DIY side skirts and a pair Z06 ducts and much of my interior in carbon fiber. I finished my first piece today-the console lid.
what did you use to make the mold? And how did you cure it? You have use a oven or autoclave? Very nice work!! I was playing around with some prepreg cf myself but have been so busy I haven't really had the time to mess with it. Plus its hard for me to get my hands on a autoclave to use lol.
what did you use to make the mold? And how did you cure it? You have use a oven or autoclave? Very nice work!! I was playing around with some prepreg cf myself but have been so busy I haven't really had the time to mess with it. Plus its hard for me to get my hands on a autoclave to use lol.
I did not make a mold. I wrapped a layer of carbon fiber around the existing console lid. I applied a light layer of resin to the lid and let it dry to a sticky tack (4-5 hours). Then, starting at the middle, I laid the fabric down. I put a layer of resin over it and let it dry over night. I applied a second layer of resin the next day and let it dry completely. I sanded it down with 100-220-400-800-1000 grit sandpaper. I put another thinner layer of resin on it. I made sure to get all the bubbles out of this layer; some people say use a hair dryer, but I just get close to the surface and blow on it, the bubbles come right out. I let it dry completely. I put a last thin layer of resin on it and used the same method to get rid of the bubbles. It looks like wet glass without a clear coat, but I bought a 2k 2-part epoxy clear coat spray to use on.
I used straight plan 2x2 twill carbon fiber fabric, not prepreg. There was no vacuum bagging or oven curing. I let the first experiment dry in the garage and decided that was not a sound environment when I discovered 2 dead flies dried into one of my parts. So, I have turned my spare bathroom into a makeshift "drying room" so the part can air dry in a dust/bug free environment. The resin I use from Home Depot self-cures in room temperature air to a tack in 4-5 hours and is solid enough for a 2nd coat in 10-12 hours and probably solid enough by then to reinstall in the car, but I am waiting 24 hours just to be safe.
Last edited by DrRaySomeDay; 07-09-2016 at 12:46 PM.
Looks good. Did you wrap the fabric over the existing padding and vinyl or remove and use some other substrate/form?
I wrapped the fabric over the padding and vinyl for the console lid. For the A-pillars I am working on, I pulled the vinyl and padding off. I couldn't think of a good alternative for the lid, so I experimented and got lucky! The console lid itself still has the same cushiony feel as it did without the carbon fiber on, which actually surprised me. I thought it would be more rigid but its not.
I did not make a mold. I wrapped a layer of carbon fiber around the existing console lid. I applied a light layer of resin to the lid and let it dry to a sticky tack (4-5 hours). Then, starting at the middle, I laid the fabric down. I put a layer of resin over it and let it dry over night. I applied a second layer of resin the next day and let it dry completely. I sanded it down with 100-220-400-800-1000 grit sandpaper. I put another thinner layer of resin on it. I made sure to get all the bubbles out of this layer; some people say use a hair dryer, but I just get close to the surface and blow on it, the bubbles come right out. I let it dry completely. I put a last thin layer of resin on it and used the same method to get rid of the bubbles. It looks like wet glass without a clear coat, but I bought a 2k 2-part epoxy clear coat spray to use on.
I used straight plan 2x2 twill carbon fiber fabric, not prepreg. There was no vacuum bagging or oven curing. I let the first experiment dry in the garage and decided that was not a sound environment when I discovered 2 dead flies dried into one of my parts. So, I have turned my spare bathroom into a makeshift "drying room" so the part can air dry in a dust/bug free environment. The resin I use from Home Depot self-cures in room temperature air to a tack in 4-5 hours and is solid enough for a 2nd coat in 10-12 hours and probably solid enough by then to reinstall in the car, but I am waiting 24 hours just to be safe.
The underside is largely covered by a plastic panel you reattach except for roughly the outer inch of the lid. If one was so inclined, the epoxy resin on the underside could be built up and sanded as smooth as the glass-like topside, but I was not so inclined. I smoothed off the rough edges so I wouldn't feel sharp, bumpy edges but I stopped sanding it at around 400 grit. It should still gloss up nicely with the clear coat, but it won't have a wet, mirror like finish to it. If you show the car or are just more picky than I am, it would probably be another hour of sanding up to 1000 grit, then another 2 layers of resin, then another hour worth of sanding.
Long story short, I did not finish it to the quality of the top but will post pictures once I get the piece completed with the clear coats
Amazing work! I must ask, you went over the padded cover, used multiple coats of finish material and it remains flexible without cracking?
I want to do something with my radio bezel, but I don't want shine and wouldn't mind some texture. Is that possible?
Amazing work! I must ask, you went over the padded cover, used multiple coats of finish material and it remains flexible without cracking?
I want to do something with my radio bezel, but I don't want shine and wouldn't mind some texture. Is that possible?
The cushion is still flexible. It has an initial coat of epoxy resin, the carbon fiber cloth, then 3 or 4 additional coats of epoxy resin. I test fitted it in my car and while driving it felt exactly like the vinyl padded console lid armrest I was use to. It surprised me. I can push down on different areas and it is spongy just like OEM.
As for the radio bezel...that is a nightmare. I have worked with CF and resins for a couple years on different DIY projects and that was the first part I attempted in the Vette. There are just so many curves and holes in it that it makes it an absolute nightmare to attempt. Over winter break (medical student = winter, spring and summer break = car time) I spend probably 4 hours a day for 5 days and 3x the necessary carbon fiber fabric to try and get it right. I said "f-it" and even though I'm broke and my wife would kill me, I bought a hydrographic dipped carbon fiber radio bezel for $300. I told my wife it's the real thing and she was proud of me for how good it turned out. Needless to say, I set the bar pretty high and have become a perfectionist for these other wrap jobs so she doesn't realize I dropped $300 without asking lol.
All the interior parts are DIY possible except the radio bezel. You will spend an equal amount of money (or close to it) on materials and the equivalent of a 40 hour workweek to MAYBE get it looking as good as a hydrographic part.
Amazing work! I must ask, you went over the padded cover, used multiple coats of finish material and it remains flexible without cracking?
I want to do something with my radio bezel, but I don't want shine and wouldn't mind some texture. Is that possible?
I thought about this, and if you DONT want shine and want some texture, you should give 3M's 1080p vinyl carbon fiber-like wrap a shot. It is matte finish, has awesome 3k 2x2 twill texture, and is infinitely easier that carbon cloth and resin to apply. I still think it would be REALLY tough to get the vinyl sheet to give you all the curves, bends and holes required from the radio bezel but its cheap enough to give it a shot. If I recall correctly, I tried the radio bezel once with 3k 1080 wrap from 3m with no success before trying 4k vinyl wrap from china. I was still not happy so I attempted real carbon fiber skinning multiple times before accepting defeat and going with the high gloss hydrographic.
I was referring to the dinoc as well. I pretty successfully wrapped the one in my Z with perf. Naugahyde and my heat gun. My wife helped me by adding a seam in the area near the ignition key. I think I'll be all right with the dinoc, but if not there's always something else. How about wrinkle finish paint?
07-09-2016, 11:33 AM
My DIY Carbon Fiber Console Lid
Well done!! 
Turned out perfectly. Looking forward to a picture of it installed.
