How to Make a Forged Carbon Fiber Engine Cover [DIY]

#carbonfiber #forgedcarbon #enginecover
How to Make a Forged Carbon Fiber Engine Cover [DIY]
How to Make a Forged Carbon Fiber Parts
Making Forged Carbon Fiber Engine Cover
How to make a mold for carbon fiber
How to make a fiberglass mold
HANKUK CARBON
Website : www.hankukcomposites.com
Linkedin : / hankukcarbon
KZbin : / hankukcarbon
포지드 카본 엔진커버 만들기 [DIY]
포지드 카본 파츠 만들기
카본용 몰드 만들기
FRP 몰드 만들기

[@snapchat7293]

What a mission, this makes the $300 carbon cover look like a great deal

[@dankcincy]

It's more about the process than the part. Playing the long game bud.

[@bl4ckde]

The differece is that he can reproduce that cover with his form several times - so nothing for someone who wants to do it for one cover. You can simply overlaminate yours and vacuum it. Will do the same

[@TqmmPl]

I'm waiting when you'll start to make carbon body panels like fenders, hood, doors :D

[@kevindery]

@Joe cure a corner at a time 😂

[@TqmmPl]

@Joe 15hours with heatgun? :V

[@wahyujayakusuma9670]

Hell yeah

[@crispcarguru303]

lol that would be cool!

[@jamesofallthings3684]

This isn't carbon fiber to begin with so it'll probably be a long time.

[@graze2fnt733]

진짜 열정과 노력, 재능까지...정말 멋져요!! 카본이 비싼데에는 다 이유가 있었군요!!

[@g45h96]

I like the idea of using carbon tow as just a surface layer on parts that don't need the strength of forged carbon. You get the look of forged carbon without the mold and workholding complexity, and also on a real carbon part.

[@icehawk3442]

(Forged carbon is less strong than regular twills, it is just beneficial in cost for production, and offers more compatibility for awkward shapes especially on smaller parts. It's also lighter for the same volume so it's good for non-structural or partially-structural parts that don't need the extreme properties of regular CF)

[@g45h96]

@@icehawk3442 forged carbon can be weaker or stronger than twill or weave, depending on use case and manufacturing. The randomly oriented strands are incredible for small, densely packed, complex shapes. Not so much for large, thin, or flat pieces, where the benefit of long, continuous fibers would be apparent. Forged carbon is made by throughly wetting the fibers, and curing under high pressures (some sort of mold and clamp system, usually. This squeezes excess resin out, and packs the fibers more tightly together. The purpose of resin is to transfer load from one fiber to the next. Therefore the less space between fibers, the less the strength of the resin comes into play, resulting in an overall stronger part. Tightly packed, randomly oriented fiber also significantly reduces the concern of delamination.

[@Mortimusmoose]

You're talking about two different things. First there's the wet laminate version, (where you...as you say, wet out the fibers then clamp molds together) then there's the real stuff (SMC and BMC) that's made in a multiple piece mold, and is a prepreg system that is pressed together in a heated platen press. Even SMC/BMC is *almost* as strong as woven fiber (both prepreg). However, SMC and BMC are being used in structural automotive applications now as well. @@g45h96

[@mammoth-puppy3246]

I love watching it come to life when you spray the clear.

[@foesfly3047]

Your demonstration method is more effective than most and your video editing techniques make your tutorials more interesting and enjoyable.

[@techtrip8942]

dont add stupid free music to these

[@ae29productions]

​@@techtrip8942 he could add slow background music like Carboncitizens they are made for automotive creaters to use for free

[@SirSlyBird]

Beautiful. I'll be trying this method for the panels on my sled project. Love how you taped the tool and overlayed it with plastic instead of shoving the whole thing into a huge bag. thanks for sharing. 👍.

[@vocks85]

Very happy to see you post again. It’s been a while. Can’t wait for the next one!

[@russellg7382]

Beautiful! I want to do a bunch of stuff in my upcoming build but idk that I have the time or patience to do it. Looks incredible!

[@toshizou3104]

本当に凄い！　素晴らしい技術とセンス！　尊敬しかない。

[@TragicEndings]

the most straight forward video I've come across

[@pedgarage]

You should use transparent gelcoat as first layer, it will save you the process of giving one hand of epoxy at the end

[@drz7787]

진짜 정성이 대단합니다!!!

[@danboyes7477]

Fantastic work, as always, well done 👍

[@user-jc8bq5eb6s]

Ну наконец то ,я уже соскучился за видео роликами ! Как всегда в своем духе с юмором ))) ,приятно смотреть и поучительно 👋👍

[@user-hw4kr3ec5q]

Вроде и без слов, а улабнуть заставляет)))))

[@user-jc8bq5eb6s]

@@user-hw4kr3ec5q Ну да это точно . У него такой своеобразный юмор))) ,я всегда прикалываюсь с его видео . Молодец . Вообще у него там много приколов в роликах .

[@artiomdavidov2138]

@@user-jc8bq5eb6s единственное не хватает салфеток анимешных))

[@user-jc8bq5eb6s]

@@artiomdavidov2138 Это точно ))

[@therealjoshtodd]

that's dedication dude. very impressive

[@user-zb1rj7pw3y]

와 미쳤다 나도 대학다닐동안 혼자서 거푸집 만들려고 노력했는데 진짜 디테일이 미쳤다 난 저런 작업 방법은 생각도 못했어 미쳤다

[@Key195cm]

이분영상보면 시행착오가 많아서 ㅋㅋ

[@curlsalot91]

Finally someone understood how to edit!! Great skills overall tho. Keep following what you love. Thanks for this Vid!

[@Resqueda01]

Amazing job buddy! Looks great

[@user-jx2ov7gc5v]

오랫만에 올리셨네요~~👍👍👍👍👍

[@zolkazoombalambooska8901]

beautiful and wholesome tutorial.

[@minipineapple45]

the king has blessed us with more content, all hail the king!!!

[@sttng3.3r_68]

Oh wow, I've been taking CF for granted. What a journey 👏 So glad there are ppl like you out there but I'm gonna have to just cough up the money instead lol it's faster 😆

[@Harrison6624]

This video just confirmed I'll save my time and buy one.

[@rahdigga6031]

You sir are a wizard. My only critique would have been to leave the embossed M and stripes in place but maybe it would have made the process more difficult. Still, great work.

[@taylorjones5370]

Naw its not really any harder all the same steps basically

[@festerartix]

I love the CAD construction part most. Clicking sound remembers me to my own construction in CAD - also could be Sound of playing Diablo 2

[@sayitekici7430]

Im in love with your channel I love carbon fiber so much that i can make all what i have in carbon fiber e.g. all of my car parts that are removable

[@MRKchallenger]

Oh c'mon Mr! We need more of your masterpieces on video! More! 😀

[@8000khids]

Amazing workmanship, I dip my hat to you sir

[@Mrf0rtyfive]

Dude that was dope af!! Awesome! Thank you for giving me more tools to succeed once I’m outta prison!

[@Nanan00]

Not sure if you have had a chance to use one but the oscillating multi-tools from Dewalt etc. work wonders at cutting fiberglass and carbon fiber and kick up a ton less dust than the grinder and cutoff wheels. I have not done a forged carbon project yet, this makes me want to give it a shot.

[@renny_composites]

I dont think there is any difference in cutting normal Cabon Fiber or Forged Carbon.

[@moriwaki80]

Yeah agree, I use one of those tools and a water spray to keep dust down.

[@compspace]

great work, really enjoyed it :)

[@kramer26]

I've used this method a lot and still getting used to it... nice piece, would have been good to see it fitted on the actual car.

[@rush_g70]

오랜만에 영상 좋아요!! 👍

[@nixadroneguy6319]

That's beautiful!

[@ACupOfDuck]

This is pure po0rn! So satisfying to watch! Can't wait for you to make widener for your car!

[@temyraverdana6421]

WOW, amazing job!

[@nato_otan1949]

дуже крто! дивився на роботу американців то просто жесть)) ти чувак профі!

[@Dekpk90]

차에 껴있는거도 보고 싶은데 아쉽습니다 ㅎㅎㅎ 역시 대단하세요

[@user-gm2jl5ep1l]

점 점 더 기술력이 상당해지네요 ㄷㄷ

[@vinipess]

Beautiful work

[@swave7585]

Learning fusion360 comes in clutch when making cf parts for sure.

[@chrikimck]

영상.기다렸습니다😊

[@Christopher42769]

안녕하세요! 포지드 카본에 일반 카본천 추가해서 적층하셨던데, 포지드 카본으로만 2세겹 정도 두께로 적층하면 문제되는게 있을까요?

[@sajidmohammad3190]

Fantastic!

[@garydeandeery]

Brilliant job. Iv done lots of parts aswell. Like skinning and vacuum bag to this Lots of work but looks good I did a coffee table too

[@BB-pf2cs]

When you did the table did you use a vacuum or just brush and roller? How'd it come up?

[@stefanwunderlich9880]

Endlich mal wieder ein Video ❤

[@BCCFERMBIZ]

Wow, I would love to do this to my airbox and cover for my Mercedes-Benz.

[@ivanplus_]

О да мужик!! Я понимаю эту боль, когда не отходит жертвенная ткань. Настрадался я с ней. Теперь использую перфорированную пленку, отходит шикарно!!

[@oh5148]

Awesome I’m working on a carbon fiber roof for a Polaris RZR

[@Vas1984]

Looks amazing. Huge effort though

[@Thedjcodeman]

love it, great video

[@Vusseyv]

Awesome job

[@vicentiuolaru3815]

Good job. Amazing!!!

[@thealternativefactor6694]

Amazing job. I see why real CF parts are so expensive....time and labor.

[@princetonaudio]

thank you so much!!

[@user-qg3qy7yk5b]

혹시 curing 과정을 왜 거치는지 알려주실 수 있나요? 주제 ㅡ 경화제를 섞어쓰는 에폭시가 아닌 열경화성 에폭시를 사용해서 그런건가요?

[@evilfish456]

Awesome!

[@dannybellew9557]

Hi m8, thanks for sharing this, I love a DIY project, plus I own a BMW 430d, so might have a go at this. Question: can you not just coat the existing cover in carbon and leave it at that, instead of creating a mould, etc? Or will the carbon come away from the plastic over time? Thanks!

[@HANZLIM_MARKETING]

Omg thats allllooooot of work 😱😱😱

[@tonn333]

What is the weight difference??? Why not show how it looks on the engine compared to stock?

[@316i8]

First of all : it's amazing. I ve subscribed and watch a lot of video of this kind, because i'm drawing plans for a custom model. It has a lot of small-size parts, like the one in this video. Here is my question : What kind of syringe are you using ? Looks like some special-clothes bag vaccum. I was considering buying a electrical vaccum pump but your solutions seems to work very well. What negative pressure can you achieve with this syringe ? I can't see the figures on the gauge. Thank You and keep it up !

[@PowBamZing]

This is amazing. Makes me want to give it a go. Can you use the mold a second or third time?

[@black.pandora]

Good work bro...nice...

[@dhanashishwarpersadcarbonIsh]

Awesome 👌

[@artongashi6206]

Very nice job..

[@leobats14]

incredible.

[@elvolad]

you are so sharp

[@GG-MUSIC418]

fantastic job! what kind of carbon fiber weaves do you use?

[@JCnordic2983]

Looking gd my friend!

[@krystiankalinowski6757]

Can you please post the weight comparison of the final part and the plastic original?

[@thediddly]

My god this channel is slap happy

[@hotboyracing]

Hey great video, I have some small body pannels for rc cars I wanna have done in forged carbon fiber how would you go about smaller molds?

[@jeanfrancoispoivre4438]

Super top ta pièce en carbone 🙏

[@JCnordic2983]

I would've recommended fi ish sanding with your palm, it's a malable surface. We use to wet and finish sand with our hands , that way it allows a more equal pressure.

[@K03sport]

So, why not keep "M Power" and other slightly raised details? The fiber shards will mold around them in the vacuum. I get why you smoothed the cover, but have you tried leaving logos or similar ID marks in place? What about adding colored "ember" bits (blue and red) to support the M tricolore?

[@remcovanvliet3018]

It's a cool idea, but doing it on KZbin might land you in trouble copyright wise, if BMW decide to be dicks about it and call their lawyer.

[@LanzHD]

Amazing!! Looks complicated af thi

[@airaime313]

Beau travail ! 🇨🇵😎👍

[@cpd7809]

Wow wow wow 🎉🎉🎉😮😮😮 the best !!!!!!!

[@jorickver]

How you manage not to mess up your floor is beyond me

[@Cinemaaereo]

Whyyyyyy god a Manual vacuum Pump?!?! ahahahahahaha EXCELENT job!

[@FsprJM]

금손 ㄷㄷㄷ

[@keirenbudding8105]

Sware down this little engine cover got sanded down more than most painters sand an entire house 😂 top job!

[@damag0chi.]

열에 의한 수축또는 변형에 대한 부분이 궁금합니다

[@Death_Knightmare]

오랜ㅇ산에 영상올라왓네요.

[@jeremyhernandez7450]

Fantastic work, now where can I get a bucket of chopped carbon like yours?

[@AndersQ]

Awesome job, as always. Wondering what part of this did you find to be the most difficult?

[@izmepablo]

Cleaning up the mess.

[@BB-pf2cs]

That grinding inside 😂

[@viajando-con-edgar]

Exelente trabajo

[@user-ng2zp3yy6c]

Здравствуйте. Очень красивое изделие. Подскажите пожалуйста какой Вы используете клей в конце видео для склеивания композитных деталей между собой.

[@Boubson]

All this work for an "always hidden" engine cover... so beautiful anyway.

[@user-bb2ew2xw4s]

대단하네.

[@quodn3638]

Amazing

[@user-ol3pu8hg9j]

형 살아있었구나

[@nz5503]

Brilliant, how much work you need to do simple panel. Always it looks much easier than in real life. Thx

[@NeverStopRc]

카본은 정말 정성이;;;

[@suxfall9530]

amazing

[@elmerhomero666]

Why you remove the BMW logo and M Power logo? difficult to mold? the carbon don't get inside the grooves?

[@ProjectCarTV]

How many hours was the process from start to finish with this?

[@icehawk3442]

I know that is great craftsmanship and certainly sharing this with us is a positive. It's just sometimes we do a project asking if we could without thinking if we should. If you were going for non-structural aesthetic upgrade, there was no need to specifically put the twill CF ply underneath the forged. If you had to put twill as you couldn't put the chopped tow under a compression mould, you didn't need to use the vacuum infusion / oven cure type of resin system and could have done with a simpler non-infusion type. Just needs an insulation layer under the cover (which many modern engine covers natively have actually, their role is to retain heat in cold months for better efficiency so the top layers of the cover would never get hot). If you didn't need to go for the twill underneath, you wouldn't have needed a fibreglass mould or oven and could have done it on a 3D-printed mould. A fibreglass mould is often good for making tens of copies of a part, which is nice if you're going to charge 9 of your buddies to make theirs but otherwise is not an optimal usage of your time or resources. If you had otherwise wanted strength from it, it would have been way easier to inbuild a bit of cross rib to the part design by digging lines into a negative mould on the other side and continuing to forge it with the shaped braces underneath. If you didn't know how to model a 2/3-part mould as complex as this, you could have used the original part that you destroyed anyway, and made that a mould. Part would offset and be slightly bigger, but since you'd made the mounting points yourself it wouldn't be noticeable or make a practical difference. None of this takes away how well it turned out and how much effort you put into it, it's just in design very often the first questions are 'do you really need it made to that spec' which is fundamental in functional pieces. I get that for such a large part compression moulding is difficult and driving it with a vacuum infusion twill backing is one of the cleverer workarounds, but surely chasing this aesthetic defies design logic for functional aspects? To those wanting to do it but finding it too hard, with some decent modeling knowledge and modeling time you could cut the resource spend ($ and time/expertise/equipment) more than half in manufacturing. In fact with a bit of modeling knowledge you could even design your own engine cover, all you need are the original bolt hole points. That is the positive inspiration I got from this video -- since even that would be cheaper and quicker than as shown.

[@icehawk3442]

TLDR: forged carbon was originally invented to help reduce the effort required to make a carbon part. Just make a mould covering both top and bottom faces, mix some fibre and resin, press it really hard with some C-clamps and you're done. This build unfortunately sacrificed all of that convenience and got the forged finish while effectively going through the huge pains of all the traditional composites process. It's impressive... but a wasted opportunity compared to how much easier it could have been.

[@RandomDudeOnYoutube]

How Would i go about making a Front Fender for a MX bike in "real" forged, Not like this ? I mean i would just need the 2 Mould Sides to press together right? It would be kinda Hard to get them right i Feel like cause there's no flat edge

[@nutmodify]

Finallyy!!