Dual projector carbon fiber headlight update

[rxrep]

Usual disclaimers that ths project is not done, and all of the imperfections you can see are known and will be gone as more resin layers are applied and sanded.



Turn signal trim:



This trim is complete and is matte finished. The rest are all still gloss because I haven't sanded level yet. You can really tell the difference when holding the matte trim next to the stuff that's still gloss.



Here is one for the DIY, lol. Second headlight housing just after overlay applied.



Here is one just to see how lens trims look in rough pre-sand stages. They aren't clicked in place as I have to trim CF on the main housing first.
Still a little tack to them so I'll leave them for the day and start in to first sand-downs tomorrow.



And another without second projector mounted in place:



Turning out good so far for an overlay, especially. Not too much sanding needs done.


Should have both done by end of week. Then I need to do test-runs on the LED's to make sure I don't have heat issues. Then I hope to have functioning auto-dimming S5-look LED's in addition to the dual projector housing.

[El_Chapusca]

Wow that looks really cool, can't wait to see the finished product. keep us posted

[AudiA4Turbo22]

i am 100% impressed good work Lee

[ehfour]

Amazing work!

How hard is CF to work with?

Similar to Fiberglass?

[UnkleGatsby]

I have always wondered about this. Looks like its coming along swell. I am excited to see the finished product.

[rxrep]

Amazing work!

How hard is CF to work with?

Similar to Fiberglass?

Thanks. Very similar, except you really have to worry about how the flow of the weave lines looks. Keeping weave straight in places where it should be straight is tough. Just takes patience. But other than that, it's different from how I normally lay fiberglass in that I usually saturate the fiberglass weave first, whereas on CF, I apply resin to the surface of the part to be covered, wait for it to become very tacky (using a heat gun helps make this faster), and then gently push the cloth in to the tacky resin. Start in the middle and work out. I use various tools to push the cloth in to the right angles and nooks. If I didn't wait long enough on that resin, the cloth won't stick well in tight curves or right angles. If I have a trouble spot, I use a heat gun to dry resin until the clotch holds. Once the initial overlay resin is dry, I then start slapping on top coats of resin. I usually start sanding high spots by about the second top coat. I keep re-applying and sanding out after that until surface is smooth. Then fine sand and spray with matte clear.

[martini]

i hope your taking pictures for my site woman!

[F16HTON]

FWIW, carbon fiber is used extensively in many hobbies (rockets, RC cars, rc airplanes, Rc boats) and there are tons of videos on YouTube that show the processes.

I really like what you made, personally though, I would have roughed it in fiberglass and bondo and then did a vacuum bag overlay.

[dirtybrd]

Great work but I've never been a fan of CF.

[Turbo1A4]

thats awsome i am a carbon fiber whore i need to learn how to do this

[dirtybrd]

To me it looks like black fiberglass.

[F16HTON]

http://www.youtube.com/results?searc...acuum+bag+carb

[rxrep]

Vacuum bagging is useful when multiples are made, or when you have made a mold and want the final product to be just carbon fiber.
Since mine is purely aesthetic in nature, I opted for the overlay. I need all the inside plastic to hold the projector housings in correctly. It has to be sanded smooth, which makes many extra steps over vacuum bagging, but I wasn't about to buy all I'd need to vacuum bag for one project.
Longer process, but it's actually cool seeing it take shape from my own elbow grease. Sand, layer, sand, layer, buff.

[rxrep]

i hope your taking pictures for my site woman!

What are the things in the first post beeyatch?

I'm taking pics as I can, but unfortunately none during some working processes. Can't stop what I'm doing to take a pic. Especially when resin, epoxy, or fuzor is involved.

[martini]

get someone to stand over your shoulder!!

What are the things in the first post beeyatch?

I'm taking pics as I can, but unfortunately none during some working processes. Can't stop what I'm doing to take a pic. Especially when resin, epoxy, or fuzor is involved.

[sandspeed]

Seriously though, CF the part of my headlihgts that normaly gets blacked out in Joey mods. I have no faith in my own skilss to do this. Can I bribe you with Euro parts?

[rxrep]

Seriously though, CF the part of my headlihgts that normaly gets blacked out in Joey mods. I have no faith in my own skilss to do this. Can I bribe you with Euro parts?

I think CF overlay is no harder than painting them. Shit can get 'spensive though.
If I wasn't balls deep in my own projects I'd consider it. I'm already consumed.

[jon102034050]

jeez, every time I see your work I just get jealous, these are going to look so sick when your finally done

[whiteUSPflow]

bad ass man i would pay really good money for a set of thows. i thought about doing it myself but i was going to just do the inside trim plastic piece. but wow they look amazing good job!