FuryRebuild
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| posted on 25/7/13 at 09:42 AM |
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CarbonMan Mould Making course write-up
So, a week or so ago, I attended the Carbon Copies Mould Making Course, and I thought I'd put in a
write-up because I was so impressed. I decided to go on the course because I was soon going beyond the flat-panel CF work I was doing on this fury and
thought ... £180 of tuition will take me way further than multiple days of bumbling around in the workshop and getting it wrong.
The course is organised by Warren (owner and self-admitted, unapologetic, carbon-fibre and composite addict). You get there at 9 and brace yourself
for a full-on day of mould-making, part-taking, tooling, techniques, tips of the trade and general how-to-do-it, gaining advantage of all of his
ex-aerospace years of carbon-fibre work.
The workshop is in an old cloth mill in Crescent St, Todmorden which caries a certain irony. The training room upstairs is massive, and on the walls
are lots of parts Warren's made, and lots of moulds on benches for you to see just how (for instance) you would make a cycle wing. You get a
tour of the techniques when you want. Lunch and infinite cups of tea and coffee are included and not skimped on. This is an important point because
Warren was willing to go on as long as I was and I needed to leave at 7pm  On the way you have a right giggle and plenty of time for reflection and
questions. In fact, Warren encourages interruptions and wants you to be totally sure you've got something before he moves on and also sure that
alternative approaches (which he encourages) are discussed.
The plan for the day is to make a mould and take it home to use it. As such he asks you to bring a pattern (or for our US cousins: a buck) that you
want to make a mould from and you can do that during the day. You actually get something concrete in your hands at the finish.
The course doesn't just go into this though, because you'd not get the mould made and set in the time for the course duration, so he does
it a little backwards to squeeze the most out. After a general discussion, much cooing at the lovely things hanging on the wall and another cup of
tea, you make a mould from one of Warren's existing NACA ducts. This means you can do the "how to finish the mould" bit on an
existing pattern before you then spend more time making your pattern.
We used the Easy Composites epoxy mould making kit for this because it's quick and Warren reckons it's the best for the job. I should
point out that neither he nor I are associated with these guys. They just supply good stuff to their own formulas. Warren also goes into how to make
moulds using polyester as well, and that crops up later when you're starting out making yours.
Warren took us through the mould-release process, and then guided us as we mixed, kneaded, painted and dabbed the stuff on in the right order (and
you're encouraged to use plenty-lots) and let it set. Out it pops and there you have it, a mould. We went through the issues we may get, and the
slight imperfections we may create, and lots of time was spent discussing mould-repair and maintenance and how to put the imperfections right. This
was a good morning spent.
Here is the mould from which I made a negative mould.
 
Description
LUNCH.
Afternoon was spent discussing the polyester resin system, barriers and finish, etc so that you can make a mould with the cheap stuff and still take
an epoxy part from it. He also discussed the merits of using kingspan bonded together with bog (body filler) for forming because it's lots
cheaper than the modelling board that is used for cnc machining. Barriers discussed were high-build primer, 2k clear coat and gel-coat.
I bonded my bits together, and Warren had a lot to say about my mixing technique but I got there in the end. After bonding multiple layers (I was
making a dash-pod for the new dash I need to make), I carved them into rough shape with a knife, and then we got to sanding the right shape in place.
Once done, layers of "whatever cloth scraps you have lying around" are used to cover the shape, which is set with polyester resin before
bog is applied and sanded smooth. Even with bog application there was advice about how to apply for the least sanding effort. I will not be a good
cake icing person.
By the time the part is sanded to the right shape, the day is about over, but that's the point where you can apply the techniques from the
morning at home yourself to finish off.
All in, a great day, a good long course, value for money and a great laugh. It's a treat to see just how much Warren knows, and that he shares
it all and really wants you to leave with a mould and pattern in your hands that will be genuinely useful for you.
Definitely worth it.
When all you have is a hammer, everything around you is a nail.
www.furyrebuild.co.uk
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olimarler
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| posted on 25/7/13 at 10:24 AM |
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I would love to this course!
How often does he run the course?
Cheers
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Carbonman
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| posted on 25/7/13 at 06:47 PM |
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Bloody Hell Mark that was a write-up and some !!!!
It was a pleasure to have you on the course. Glad you enjoyed it. As I said on the day the course doesn't end there, if you need any help/
advice with your projects just pick up the phone or pop over and I will be happy to help.
Who knows I may see you on the next Resin Infusion Course.
For those interested the next courses are scheduled for 3rd and 10th August.
Regards Warren
Carbon Copies Ltd
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NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
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FuryRebuild
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| posted on 10/8/13 at 07:14 PM |
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Just quick follow-up to the course.
I've made my first mould and have had some problems sealing it (my fault) - I didn't clean off the spray-tack before putting epoxy down to
seal it - end result was a mess of a moulding service. Styrene and epoxy really don't get on.
So, one call to Warren where he points out what I got wrong and gives me the science behind how the two materials interact, into the car I jump. After
a nice welcome and a cup of tea, he gets out the orbital, sorts the surface out and then sprays it in 2k clear coat for me. I now have a nice shiny
mould ready to take a panel off.
That's great after-sales service.
M
When all you have is a hammer, everything around you is a nail.
www.furyrebuild.co.uk
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Carbonman
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| posted on 10/8/13 at 08:27 PM |
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quote:
Originally posted by FuryRebuild
Just quick follow-up to the course.
I've made my first mould and have had some problems sealing it (my fault) - I didn't clean off the spray-tack before putting epoxy down to
seal it - end result was a mess of a moulding service. Styrene and epoxy really don't get on.
So, one call to Warren where he points out what I got wrong and gives me the science behind how the two materials interact, into the car I jump. After
a nice welcome and a cup of tea, he gets out the orbital, sorts the surface out and then sprays it in 2k clear coat for me. I now have a nice shiny
mould ready to take a panel off.
That's great after-sales service.
M
Unfortunately as from the 1st September my accountant informs me that I must start charging for the tea & coffee, you can thank Starbucks and
their "creative accounting" for that 
On a serious note be sure to let me know how the panel turns out.
Warren
Carbon Copies Ltd
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NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
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Paul_H
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| posted on 10/8/13 at 10:16 PM |
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Sounds like a really good course and kudos to carbon man for running it if it was not for people who are willing to pass on the fruits of years of
work those of us doing this as a part time hobby project would get nowhere
Would love to do this course but would have to be after xmas I think now  will be keeping an eye out for course info in the future
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unijacko67
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| posted on 9/6/14 at 09:47 PM |
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Does Anyone have any info on Warren (carbonman) as he hasn't been on line for a while and I've tried his mobile a couple of times. I know
he had been having a rough time and hope he is ok as he is a top bloke.
http://www.kittenkitcar.co.uk
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