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Thread: Lyrebird Cycles

  1. #161
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    Default DIY Prepreg Redux.

    I have previously covered DIY prepreg using high TG epoxy and woven carbon. Until now unidirectional prepreg has been a problem but I've worked out a way of making my own, which means I can use the higher spec tow I use for filament winding. I am using Toray T1000 here which is 300 GPa vs about 240 for the commercial prepreg.

    I set up the filament winder with a drum of appropriate diameter covered in non-stick paper:



    and set it to hoop winding with an appropriate feed rate (2 mm for the 12k tow):



    (sorry for the shit pic, camera autofocussed on the winder not the drum).

    Whe finished I simply slice the non stick paper and cure in the oven to beta stage et voila, unidirectional prepreg:


  2. #162
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    Default Re: It's been a long time coming

    Quote Originally Posted by Colinmclelland View Post
    Hi Mark,

    Can you tell us more about the carbon dropouts in FNL?
    It's been a lot more than a week but here they are:


    Polydrops

    Sorry but the combination of black dropouts on black carbon and my shit photography aren't going to light the world on fire.

    They worked out well but the next frame will use Paragon's "Bolt On Brake Interface" which should be easier to adapt, I am hoping it work at least as well.


    K_Bike_Scales

    On the other hand, I believe this is the lightest wood frame yet made by some margin at 1056 g. My wife says I should have made it ten grams heavier.

    I'd post a pic but I forgot to take any of the frame.

  3. #163
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    Default Re: It's been a long time coming

    Quote Originally Posted by Mark Kelly View Post
    It's been a lot more than a week but here they are:


    K_Bike_Scales

    On the other hand, I believe this is the lightest wood frame yet made by some margin at 1056 g. My wife says I should have made it ten grams heavier.
    It must be child sized though

    Like the BB evolution...took me a while but I finally got the 10g thing!
    Colin Mclelland

  4. #164
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    Default Re: It's been a long time coming

    Small to medium, to fit a 165 cm rider.

    Re the BB thing: thanks, this is my first attempt at something I am very hopeful for. It's an adaptation of yosegi zaiku, a traditional Japanese inlay technique. Each of the little bands is a separate strip of wood ~1mm wide, the thicker bands are simply two strips, so there are 30 to 40 individual pieces in each tile. The advantage is it's much more adaptable than the single wooden tiles I previously used. It looks a little busy close up but from further away it's actually quite subtle.

    I will eventually post up a little description of how it's done. I found the existing information a little frustrating as it is all hands on: do this and this and this and you'll get this result, while I wanted to know how to calculate the shapes and angles from first principles. To that end I worked out the trigonometry that governs the technique so it's all good now.

    After doing this bike I realised that I've been doing the joints backwards all along, I am going to try defining the joint area to have a constant width inlay band then adapting the tube laminae to fit that. I will also drop the carbon webs, they are too much of a PITA to do and I've never got them to work quite as well as I wanted.

  5. #165
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    Default Re: It's been a long time coming

    Thanks Mark. The old yosegi zaiku.

    Quote Originally Posted by Mark Kelly View Post
    ...snip... I will also drop the carbon webs, they are too much of a PITA to do and I've never got them to work quite as well as I wanted.
    Just for kicks, let's pretend I'm not sure what you are talking about here....
    Colin Mclelland

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