Carbon Sheet

[bromvw]

Can anyone advice on cutting carbon sheet . I want to make a custom top deck like a super champ to fit my funco buggy champ build . Space is very limited due to the size of the new side pods . I'll have to fit a battery length ways rather then across the chassis . I know to wear a mask ect but any other tips would be appriciated .

[Leethal Driver]

I used a dremel cutting disc and one of the white tyre paint pens to draw out the stencil I wanted to cut for my Astute chassis plates (clicky), worked out ok but very, very dusty so do it outside if you can. Take your time (although the sheet will cut very easily), and will need some sanding afterwards but should be ok.

[Percymon]

Not much you can do about the dust, except the usual cautions of goggles and a mask - outside is b etter but not in an area where any carbon fibres might be picked up by small feet or pets. Seal any cut edges with CA glue afterwards

[OCD]

Not much you can do about the dust, except the usual cautions of goggles and a mask -

+1 on the safety goggle and filter mask

Additionally you can also use plain water to keep the dust down.

[oz-trash-cowboy]

I have had success cutting with a fine hacksaw. The sheet was clamped with wooden straight edge to cut against. Cut edge was then clamped in a vice between two sections of 90 degree ally and dressed with a file for the straight bits. Yes, the dust is deadly, use flowing water or mist.

[bromvw]

Thanks guys that was how i was thinking . My farther in law also has a electric tile cutter that has a water jet/bath . I wonder if that would work for the larger cuts ?

[Kokuzu]

Thanks guys that was how i was thinking . My farther in law also has a electric tile cutter that has a water jet/bath . I wonder if that would work for the larger cuts ?

It does. and even for very small cuts. off course, i have not seen the setup of the waterjet from your father in law so you might run a test cut first to adjust settings.

2 quotes form another forum:

...Your not going to run into blow out on the back side of the CF when watering jetting, unless your CF is to resin starved or too much resin. As for the holes, the smallest I had cut is .20" or so.

The biggest issue you will run into when trying to get this water jetted is not having the material move around on you, I am assuming these parts a smallish. The smallest I used to cut was about 10"x2" and 10 plies of plain weave. After you cut the material, you will have to apply some edge sealant-

...the dude that cuts for me at my work can cut holes down to .0625" in diameter with +- .0005" for a tolerance.

so I'd think 1/8 would be no problem.

[charlie787b]

Just thought i would add sticking masking tape on to the carbon sheet make's for easy marking with a pen or pencil,not sure how that would go if using water to keep the dust down though.

dusty stuff that carbon

[Kevin_Mc]

Carbon fibre dust is hazardous to health, be very careful when cutting it

[bromvw]

Carbon fibre dust is hazardous to health, be very careful when cutting it

cheers kev . I've worked a lot with normal fiber glass and MDF in the past so i'll take the same Health steps .

[Kevin_Mc]

Should be alright if you've done fibreglass cutting before then

[Mud-Plugger]

Should be alright if you've done fibreglass cutting before then

Fibreglass resin contains massive amounts of leukocytes!

[OCD]

Fibreglass resin contains massive amounts of leukocytes!

Wikipedia is down today, but IIRC leukocytes are white blood cells, no?

[Sayer]

Wikipedia is down today, but IIRC leukocytes are white blood cells, no?

You can see it (Wikipedia) if you disable javascript in your browser, but that's the definition I get too.

[Daves956]

Aren't we carbon based life forms? How can it hurt you then? That's what I hear from the guys at BF Goodrich Aerospace. They make carbon fiber brake rotors for aircraft. It makes me break out, so I'd recommend long sleves and gloves too.

[OCD]

Aren't we carbon based life forms? How can it hurt you then? That's what I hear from the guys at BF Goodrich Aerospace. They make carbon fiber brake rotors for aircraft. It makes me break out, so I'd recommend long sleves and gloves too.

Hmmm, by that standard, carbon monoxide should be okay as well? It's just carbon and oxygen, right?

[Grastens]

Aren't we carbon based life forms? How can it hurt you then? That's what I hear from the guys at BF Goodrich Aerospace.

I kept convincing myself that whenever I sanded carbon decks for my cars, but at last relented and got a dust mask and goggles...

Hmmm, by that standard, carbon monoxide should be okay as well? It's just carbon and oxygen, right?

... and that was partly why. Touché!

[OCD]

Jokes aside, it's the microscopic shards that can become dangerously embedded in the lining of your lungs; Breath too much of the stuff and you'll end up on a short trip to a long stay in the hospital... !

[Daves956]

In BFG there are masks and gloves everywhere but arm protection is an option. I've seen what the stuff does to the machjnes so I wanted to warn about skin reaction to even the airborn dust. It's not very pleasant. They do joke about it tho.