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手工TT碳纤维车架的制作过程 [复制链接]

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只看楼主 倒序阅读 楼主  发表于: 2007-11-07
My main goal is to do TT-frame+bar for next race season

Because I don't like
these:
-Trek TTX. VERY NICE! Price? Rear wheel cutout and brakes suck
aerodynamically.....1 in list for "go and buy".

-Cervelo P3C,those cabling greate drag while frame is nice. Profile is bad
and slow in crosswind and VERY bad when done in CF for ideal structural way.
Is seat post stiff enought in sideways @ half kW? Nice bike anyway...2 in
list for "go and buy".

-Isaac Joule is light, cheap etc. Desent in aerodynamics but definedly
weakest in three. Too common in Finland... :O)

So my TT-bike will use cabling like Trek, rear wheel cut out like Cervelo,
mini-V brakes on chainstays, seatmast like Trek, seat holders like AFH or
integrated seat (for best weight/stiffness/aeronynamics), Easton EA90 Earo fork
for quality fork, Cervelo drop outs with adjustable stoppers, integrated FULL CF/kevlar
headtube for light weight and aerodynamics and Campy Record headset. Titanium
metal parts for low corrosion.
This basically what I'm looking for:
529*811
It's comimg slowly from my kitchen!

TT-downtube:
219*531
Structurally supportive foam core (60kg/m3) +-45mm UD 320g/m2+2X UD + twill
sock. 700X80X23mm.
269*205
For comparison, 23mm is not coinsidence, it's my Vittoria tubular's
real tyre wide...
312*542
Here seen two layers, +-45mm UD 320g/m2 +2X UD. First for torsional and
second layer for bending forces. Twill will work as +-45mm UD but it's not so
strong. Geometry of 80mm wide wing will take care for bending to agains larger
direction.
174*534
Here is core foam (2X 10mm,60kg/m3) sandet to shape. Hot wire cutting or CNC
milling would be nice also doing this. 87g for 850X78X20mm piece.


Some dry CF layers waiting for outer layer and epoxy, heavy twill sock.
+-45mm UD 320g/m2 +2X UD+ 1X UD in rear wheel cutout between BB-seat tube
section for rock solid bb feel. This is not nessesery to made so torsionally
stiff as it is but I like to use that +-45mm UD since I have it "too much".
Normal twill would be nicer base layer on this part for better bending strenght.
There is only low torsinal load on seat tube....

294*619
Full carbon head tube coming for Campy Record integrated headset. You can use
in this tube 1" and 1.1/8" forks, just pick right HS, outer diameters are same.
Ideal for TT-bikes because it allows to use rare forks and wider range of them.
130mm long. There is remove fabric offcource, then suck fabric (that white) to
remove excess epoxy. Pressuring done with plastiq tape. Some twill on UD agains
breaking forces. Laminated to tubes later.


Ugly reality. Seat tube is made using clear packing tape to add compression.
Remove fabric, suck fabric (white) and tape them. You see small dots, they are
holes of remove fabric. Dark areas are excess epoxy. You should see some or
laminate is TOO dry and will be very weak. Down- and seat tube are done with
using stiff foam plates to made compression, not tape. I will always weight dry
CF and add same amount of epoxy. I shoot for 38-42% epoxy on ready laminate.
Same as most prepegs. That ~10% is safety margin to sure wet out and will be
sucked out to suck fabric. You can always calculate epoxy %. Just weight dry
fibers and read part just from mold and do calculation.

Same tube taken open. ZERO seconds sanding done! 204g @ 600mm. Look
not not factory made but very usable and strong. Needs like 10 min sanding to
look nice. Profile is 48X33mm oval . Wider than tall for low side wind
resistanse and "some suspension" to balance huge downtube profile's greated
rougtness. And add bendind stiffnes in side sides. Torsional stiffness goes hand
in hand with tubes cross section and bending as diameter to direction of bending
force...just basic physics apply. Great exsample that curing time of epoxy is
like going half for every +10C raised. Just stay under 80C to avoid crystalising
epoxy. I use normally 45-65C. Use digital temperature meter. After cure is
theing that makes epoxy really cured. Like 8 hours in 50C. Look for data sheed
for that epoxy that you use. I use now SP Systems Ampreg 22. Great wet
lamination epoxy.


418*447
Seatube drying and some ready made parts. Soon starts fun part, the real
frame building!
480*640
Seat- and down tube joined together and in BB shell. Shell is ti with 2
layers of twill sock. Cable hole done in downtube already. 890g now.
371*530
376*84
Figuring chain stays...
547*830
Lamitating process nearly finish:
513*795

504*672
456*294
589*200
Ready for test ride!
446*691
Drop out mold:
504*672
Seat stays are REALLY 7mm thin...in pix disk wheel look that it rear triangle
in not streight but it's only because I so poor phografer...
872*395
Rear brake and sifter wire housing being assebled. At night 1:30 AGAIN...seat
only as modelling look.
509*754
554*626
595*574

Testing epoxy for clear coat.
I had some leftover epoxy and I paited with fingers (USE protective
cloves!Epoxy is not bad for lungs but it's very bad for skin when wet!!). It
easyest way to get good looking finish. And surfase looks easyer then better tha
it would be if painted. Just sand, pait over, sand, paint over...
600*800
Test rides under way. Feels Good!
492*761
BB feels stiff too!
450*430
Home made in Finland.
487*885
Rider's name may be familiar to you...
519*776

Brake cable will be on left side on real CF-bar / control system.
480*640
1条评分
azuretears 威望 +5 辛苦费:) 2007-11-07

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只看该作者 沙发  发表于: 2007-11-07


With strong and wild mind, I can see that bike ready... :D




My idea to build this frame is simple, just do it light, fast and so
monoqougue as you can. I roughtly sanded core out of 30mm blue insulating foam
and laminated few 30mm UD tapes, just because foam should keep streight and
solid during main building and laminating real layers. Top tube will get more
foam to be shaped oval. Them glue BB and head tube. Add rear stays and laminate
ALL together as possible. W'll see how this will turn out.



DT,看到努力的方向了哇?
[ 此贴被solution在2007-11-07 00:51重新编辑 ]

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只看该作者 板凳  发表于: 2007-11-07
home made in finland .........

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只看该作者 地板  发表于: 2007-11-07
强帖留名。。。

看来2D CAD还是灰肠有前途的啊
从头开始做一个屌丝

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只看该作者 4楼 发表于: 2007-11-07
太厉害了!!!

77,我回来啦。

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只看该作者 5楼 发表于: 2007-11-07
强人啊,要不咱们学习下,自己做坐杆
责任,荣誉,使命.
爱是阳光,欲望是闪光,仅仅是一刹那间。欲望炫目,但是阳光是我们生命中必需的。

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只看该作者 6楼 发表于: 2007-11-07
awesome!
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只看该作者 7楼 发表于: 2007-11-07
还是比较担心骑车人的小命
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只看该作者 8楼 发表于: 2007-11-07
啊......