Let the Project BEGIN!! Our First Time with CARBON FIBER (3)

They make it look so easy online!
But really this carbon fiber stuff is slick looking! Wetted out nicely and only had to fight it a little bit. Still haven't perfected the vacuum bagging part, had a tiny little leak but definitely better than a wet layup!
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[@mikeandjenn394]

Your first part looks good. I just wanted to give you a couple more suggestions for your journey. Try to place your vacuum port towards the middle of the layup as best as you can. Reason for this is because you actually loose vacuum pressure over distance so to get an equal squeeze it’s best to be centrally located on the part. You can also use more than one vacuum port if you have them. Another suggestion is to remember that carbon is conductive and will corrode metal parts. So make sure to place a layer of fiberglass over any locations that will come into contact with hardware or dissimilar metals. It’s easier to just add a bit of fiberglass to your layup right away verse have to go back and sand the carbon to add glass later. Keep up the good work thanks for the videos.

[@oregonxl]

skateboarder here, nice job on the ramp lol. no but all jokes aside you guys bring a lot of joy and positivity into people's lives and for that I say thank you =)

[@JChadWard]

i wanted to say the same thing. Like skateboarding down the road to the ramp at age of 14. until later when a half pipe was created in the neighborhood cool. i love their channel.

[@chrislutz7557]

The foamy oil in your vacuum pump, the brittle epoxy and the shorted space heater all seem to point to excess humidity in your work space. You might need a dehumidifier. Also, you might want to put something down under the bottles you're using as weights to keep the work piece from pulling up, something to spread that weight more evenly. Pretty darn good for your first piece of composite construction, though!

[@ur2288]

100%

[@jk63396339]

The carbon fiber dust is conductive and that is probably what took out the heater. I worked in a company that made carbon fiber and the electrical panels had to be protected from it.

[@waynegage2043]

Love the hermetically sealed space you have created for the construction of your project. However don’t you think it would be wise to do all your dust producing cutting outside of it?

[@codegame027]

unless you make it crazy super thick, the rigidity of composites actually doesn't have enough deflection. Ironically, steel or aluminum has enough deflection to not deform. What I'm suggesting is when you have a composite structure with a high static load someday it will fail and when it fails it will be catastrophic. Do you know how much static weight you are expecting on the davits? I would be worried about long term static loads?

[@reestyfarts]

Like the 787 Dreamliner: 15% titanium by weight.

[@richardsprow3418]

I worry about moving forces, not just static loads, weight of dinghy amplifies movement of boat and forces on structure. Also, you talk about “arch”, which is one continuous structure, but you seem to be using flat panels to build a frame with critical joints at feet and corners. Please go talk to an engineer in Spain.

[@michaelmcauley5526]

Great seeing you guys doing your own stuff I've watched the whole boat build you guys are great ! You do great teaching!!!

[@Who.is.Clinton]

Love the community, "Sailing Yaba" T-shirt - does not go unmissed friends!

[@davidnichols147]

Fantastic, looks perfect.

[@stevebowen9412]

Get a cheap timer to run the vacuum pump at intervals to maintain vacuum a bit longer unattended.

[@dudaoutloud]

I LOVE this type of content! You are using the skills you have and growing them into something more. This is how we all learn. Thank you!

[@mikemoxley9477]

Fun fun fun to watch you two. I learning by watching and reading everything I can find to better understand the process.

[@brentbice1151]

Some comments/tips from a vacuum bagging nerd from way back... When you use a foam core with VB'ing the carbon/glass/kevlar can be forced into making a 90 degree bend. This is a bad thing (tm). But you can feather the edge of your foam core -- just sand a slight bevel on the top edges for, say, 1/2 an inch to an inch. That way the material takes a gentle bend and your top and bottom layers of carbon/glass/whatever are bonded to each other at the edges as well as to the core. Also, be careful of where your foam cores meet when using more than one piece. If there's any movement when you pull the vacuum, you can wind up with the fabric being pulled down between the cores which may lead to a slightly weaker spot. Way back when I was helping an engineer make parts for an aerobatic aircraft (ailerons for a plane called a rebel I think?) The foam cores we cut didn't go clear to the edges of the part, just nearly. I think we had an inch or so of just pure material around the foam cores and the cores had the taper sanded into them I mentioned. In our case (for the curious), we made a top and bottom part. The bottom of the aileron was like a dish (bottom skin, sides, and leading edge of the control surface) and the top was just a flat plate. Then we sanded the edges (the part that was pure carbon, no core), drilled them, clico'ed and bonded the top to the bottom and a new aileron was born. :-) Also, if there's any way you can get an on/off switch for the pump to keep the vacuum at a certain level, that's better than just turning it off overnight. Just sayin'. Yeah, I know, might not be possible. I could never afford one for my own VB'ing (making wings for RC gliders). But I'd just babysit my stuff for 8 or 10 hours so I knew I had a good (but not too hard) vacuum at least until the resin hit the D-stage. Anyway, kudos to both of ya for doing the vacuum bagging! It's a lotta fun. I always thought it was like Christmas every time I opened a bag to see the part I'd spent so much prep time on to see if it turned out like I'd hoped. And watch out for how sharp parts edges are when de-bagging them.

[@timgwaltney5770]

Reminds me of when you started rebuilding the boat…. Great start

[@Matt-e4x]

I figured Jade was a superior being (Lefthanded)

[@redbovine]

Get you a small box fan and duct tape a good quality a/c filter to the back of it. Then cut a hole in your wall and put it in there. Turn the fan on low speed and you will have a positive pressure room to help keep the dust out.

[@karnellhillscan2834]

Looking good! If you hold your epoxy cup on the sides/ not in the palm of your hand you substantially reduce the heat transfer from your hands to the epoxy that can set off the exothermic reaction in epoxy.

[@audungoksyr9812]

The epoxy probably has IPD (Isophorone diamine) hardener and this enables a fairly brittle initial cure, you must postcure at elevated temperature acording to producers instruction to unlock elongation properties.

[@MrLdangelo]

Love the content!! You guys are awesome! Nice you can work together without getting on each other’s nerves! 🎉

[@georgedaviau9612]

Make sure you get all the air out. Is most important to do.

[@rackemyt9999]

Music way too loud. I keep having to adjust the volume.

[@bmcallister4539]

Sand bags will work for weight. It’s heavy and will form to the mold below it.

[@thomashealey3246]

Maybe want to wear gloves all of the time when touching carbon or glass... BOTH OF YOUR CHANNELS ARE AWSOME!!! KEEP UP THE GREAT CONTENT :)

[@wasimhbaig]

hey jade, cut the gain on the music by 6db, the voice should come through, music should be in the background, great editing otherwise, say hi to the pups!

[@MotorboatToo]

I feel as though your mold should have some sort of skeletal framing within the carbon fiber structure that you're building. There will be some really strong forces stressing your structure, both wind loads and weight shifting loads from the dinghy, while underway.. I don't know if the foam wrapped in carbon fiber will be strong enough. I'm not an engineer and I know that carbon fiber is strong but, it just makes sense to have an internal frame of some sort for strength. Especially when you compare how the stainless steel framing is designed for the same purpose. But, It will be a treat to watch you guys learn and build this much needed extension of your home.. Really cool..!

[@richardsprow3418]

Yes I am exactly, I think the edges of your panels are doing the structural work to resist bending, need to be more like a shallow I beam than flat panel. How does foam + carbon fiber resist compression? Maybe you need to build a small model first and load test it

[@SassyPants34]

When I do boat work i have a pair of electric scissors for cutting fiber, i couldn't imagine doing it with normal scissors now glad you got a pair!

[@mykeharris8651]

Jade I would love to read your book when you get it finished. Oh and Brett if you haven't read BACKYARD STARSHIP check it out. It's a good one.

[@jdizzle11]

3rd channel for product reviews? Expedition Evaluations! 😂

[@ExpeditionEngineering]

😂 2 channels is more consuming than expected, 3 could be our undoing!

[@jeffreygilchrist1330]

Well I’m enjoying this content enough about the music you will fix I’m sure nobody could ever say you’re not workers because this project will be big bold and beautiful cheers from Perth Australia

[@deerfootnz]

Just don't imagine that carrying the dinghy on the davits at sea is smart. I have seen many mishaps .....much much safer to carry the dinghy inverted on deck. The davits are still useful every day or on short, sheltered hops....

[@davezxtt]

a little worried that when you finish the build of it it looks too flat without and curverture to the framing of it to suit the curves on the boat. I hope not tho. loving the way you both enjoy doing these projects together.

[@SaYeager]

Love the fearless way you approach the next projects. Carbon fiber thats impressive.

[@bushjeeps]

You guys are awesome! This is an ambitious project with your attention to detail it will come out amazing. I watched Mike Patey build this plane using similar techniques. kzbin.info/aero/PL9OFkVHYEhoFUPV78e3hh0TVPMhYI73f9&si=exwKUC_DVGMMvpgc

[@charleswhatley5510]

You should look at Formula one cars. The cars are built mostly with carbon fiber. They are the best with the technology and implementing carbon fiber than anyone.

[@andymarshall2201]

Guys, I am a huge fan, have followed you for years back to before you bought the boat at auction, but please dont have that background music, it’s so annoying, I am constantly adjusting the volume.

[@obwan7217]

Cool what you are trying to do..If you succeed I'm thinking the structure is going to act like a sail. As the wind blows on the structure it may cause steering issues....Hope I'm wrong..There is a reason most use aluminum or stainless tubes...

[@Kerriannecruising]

Expedition kick butt Engineering

[@Amicaner]

Super interesting stuff! The first part is done! Beautiful from far away - LOL

[@SiLLv3r_7]

Can you explain a bit on how these become finished pieces? I don't have any composite experience so I'm trying to figure out how these come together.

[@nevillekernke1844]

Just remember 2 bend one way and 2 bend the opposite way

[@johnhewett2525]

Why aren't you pulling the vacuum down onto the form rather than using weights? Save all those strands (tows) and use them to reinforce corners ect.

[@zacatack8679]

How much did the carbon fiber cost? Just wondering

[@patriciacrosbie6029]

What about bags of water for weight?

[@RobGoldstein]

Not that Jade is dirty, but don't you worry about her crawling on the carbon-fiber and getting it dirty?

[@gerrywhite9547]

Love your vids but can't deal with the loud music!

[@Roskellan]

If you are anything like me then the hours working on the boat outnumber the ones sailing it - well mine have been power boats, but you know what I mean. It turns out I quite like working on boats, who would have thought 🙂

[@nigelw.9043]

great job you are doing with the composites. Just one word of advise. I can see you are very conscious about your PPE. However, please ALWAYS where Nitril gloves when handling epoxy resin and do not touch with bare skin. I speak from personal experience that even continued small jobs handling epoxy unprotected can have adverse effect on your heath. I have developed a serious allergy as a result of composite work without PPE.

[@Piszcze1]

It may be too late but…what if you make a whole rectangle panel and then cut out your part after? It will have the curve and you will have nice clean edges. Look at the way “the Duracell project” makes panels using foam and fiberglass.

[@tiborkiss9186]

very nice work.

[@billkaroly]

What happened to your original channel?

[@willywayne5299]

That’s for when they are sailing,they land lubbing.and working on da parts right now

[@phillipmullis7904]

I know nothing about composites so I will hold my opinion. Always in joy your content.

[@lenflier3826]

Brett, no shame dude, but I think I can tell where Jade took over the video production. P.S. Her music is better, too! 🤣 No matter. I love it all. Keep it coming!

[@ExpeditionEngineering]

Well it's no secret that she is a gifted editor, no doubt better than me. But no way is her music better! (besides I pick the majority of the music for both channels) 😁

[@captainsensible298]

Epoxy settles in containers, mix well in containers prior to catalysing.

[@SirCarlosMusicBMI]

This looks like a fun but scary project. I’m assuming that these materials are expensive??? I Love so Much How you two tackle projects and just go for it. I would love to try this method just for fun 🤩 But I’m not sure what I would do 😂. Blessings,Carlos ✝️🙏❤️😊🇺🇸 from Paso Robles, California

[@brentbice1151]

You should! I had a blast doing vacuum bagging. In my case, I learned by helping actual engineers working on actual aircraft, but on my own I made new wings for an RC slope glider I had (ie, a super thin wing for going stupid fast on high wind days, a high lift aerobatic wing that was short for fast roll rates, etc). I'd find an airfoil I thought looked interesting/fun, make thin plywood forms of it (one for the root of the wing section, one for the tip), attach 'em to a foam block and then with the help of a friend, use a hot wire cutter (piece of ni-chrome wire suspended in a wooden bow with a power supply shorting on the wire to get it hot) and carefully cut the foam core for the wing. 'Took practice but this meant I could do cool things like use a thin/fast/low-drag airfoil at the root and a thicker airfoil at the tip. Then the resulting wing had better stall characteristics (the tips of the wing wouldn't stall first - less chance of a spin). Anyway, I started very humbly -- just a hand-me-down pump given to me by an A&P who worked on full-scale gliders I helped when the weather at the gliderport was no good for flying or when I had no instructor, and whatever fiberglass or carbon fiber I could get at the hobby store. I did purchase decent 24 hr epoxy. The pump was old, loud, and had to be manually oiled and I didn't have a fancy vacuum port or resin trap. 'Just used a quart jar with two copper pipe soldered into the lid so any resin that might get sucked up the vacuum hose would land in the quart jar rather than going into the pump that way. Perforated plastic can be bought, or you can just get a sheet of thin plastic, fold it up into a square pad and poke holes in it with a punch or the point of a compass. Sop cloth can be had just going to a fabric store and buying cheap cloth. Peel ply is a "nice to have" if you're on a budget. I was cheap (going to college at the time and broke) so I just sanded finished parts that were to be bonded to something later or painted. I found foam cores in scrap bins on building sites, though that was a bit hit or miss and you can probably get better foam cores if you purchase them. :-)

[@SirCarlosMusicBMI]

@@brentbice1151 That’s awesome. Thank you for sharing this with me. Blessings,Carlos ✝️🙏❤️😊🇺🇸

[@captainsensible298]

I'm a bit concerned about the laminate schedule your going to be using for lifting the dingy. Motor on it would have to be 150 to 200kg. Woven rovings are not really designed for structural applications, more for finishing. Knitted multi axial and unidirectional fabrics are more designed to carry loads. Hope it does not break, I have had that happen before, very large friend jumped up on the top of my new coach roof extension........ CRACK !!! More epoxy/glass. No one was injured.

[@grahamselby3246]

Laying out your patterns on the material to find the best usage is called nesting. Really enjoying Expedition Engineering. You two are a great team.

[@pauld9530]

Carbon fibre is tricky stuff to cut. Try carbon cutting kevlar.

[@davegrocketsurgeon7071]

Not sure how much of a pain in the a$$ this is but can you add some of your fav builds your other channel? Really love watching you guys and wish you both all the best!

[@ExpeditionEngineering]

Not sure what you're asking?

[@aw-cv7ys]

Turn the music down!!! or turn the voices up.

[@arkeyethenoo]

Yeah electric heaters and hand tools don’t like carbon fibre filliments floating round in the air tends to trip things out lol

[@Najitaka]

Enjoying the videos, but the music volume is annoying. I don't know if you can change it compared to your voices easily. I have to turn you both up to hear what you say, then the music starts mind cracking loud. Yes, I'm old, lol. Hopefully you can make the music much lower than your voices, and viewers can turn it up if they want to.

[@vendter]

You might get there eventually, but you should spend a lot more time watching videos on how to handle and layup composites.

[@dracey1778]

Please, do not go offshore with a dinghy in the davits.

[@jackdbur]

That is the whole point to davits to store your dinghy on passage. 😅😂

[@richardsprow3418]

I agree with dracey’s point- this homemade arch may not have the strength to handle off shore stresses

[@Da89soup]

So with all the shop rental, supplies, and tools you did not have are you saving money over just buying a steel kit of what you are building?

[@dansutherland70]

why build a clean tent and then use it to cut up wood??

[@ivolimbo]

Congrats guys!!! Amazing how you are so brave to start proyects like this!!!! Keep going!!!! It would be nice in visible carbon fiber😅

[@soggybottom3463]

Hi guys - I remember you were taking on a little water approaching the Azores but never saw the resolution (I have looked!) - could you say what happened or which movie covers it at all please? Best of luck with this project, great movie thank you 👍👏👏👏

[@richardlewis5950]

Howdy Youngin's , Love this new KZbin format. I read all the comments and as usual some really good comments. I woke up this morning thinking about your new fiber project. and how fortunate you are to have a 3.2k data base..Haha Well anyhow I have one question. If you sandwich your carbon fiber with foam does that make it a giant drycell battery? I'm sure you have thought about this. You guys do a great job researching all your projects.. Love you and have great hope for success in this project.

[@RandomPrecisionMotors]

Maybe consult "Duracell Project" about that Vacuuming thing for the pieces? He seems pretty versed in that sort of thing...

[@davexvs]

geez the music is too loud as apposed to the vocal audio nearly blew my head off with headphones just saying {:-) PAV UK

[@michaels1997]

Looks Great! Any reason why you didn't smooth the edges of the foam and wrap the carbon round? It would still be a tight bend, but the vacuum should hold it in place. Maybe worth an experiment.....? It's SO easy being an armchair expert! Love the focus on DIY, gives me another channel on top of Mads, RAN and MJ Sailing to get through the winter months - Best wishes from a cold and snowy UK!

[@richardsprow3418]

Since you mentioned Atlantic Towers I took a look. Frankly I would do that- it has actual structural engineering designed for significant weight and forces. Your proposed carbon/ foam/ fibreglass composite doesn’t seem to have had any engineering calculations to it, just a guess about what looks right based on no data. Please tell us you have based your design on some data? Other commenters note that while carbon fiber is strong in tension when it fails it can be sudden and catastrophic. I worry about suspended dinghy putting heavy loads on your understrength arch. I am thinking now of that carbon fiber submarine….

[@SirCarlosMusicBMI]

1st 😊😊😊😊😊

[@djabbt4171]

Be interested in how your knockoff batteries perform. I once bought a similar offering for an oldish Dell computer, that I didn't think warranted a genuine battery cost. Damn thing wouldn't even charge properly, after pulling it apart, of the individual cells, half were just cardboard tubes. Pleased to see you've got Festool for the serious tools.

[@AmeriMutt76]

Awesome work, this should be fun. The "twice as good" as the manufacturer batteries might not show out furing short term use. My knockoff Makita batteries were fine for about a year, then started overheating during charge and use, then died at about 13 months of 5 days a week use. 4-5 year old Makita batteries are still like new

[@davidperham897]

About those after market batteries, would not trust them to be left on charge unattended, too many batteries catch on fire. It is expensive to buy original ones but safer. Those batteries are scary & I think dangerous Stay Safe friends Cdn. Dave

[@johnjunior6101]

Just think now other people will be asking you how to use this method.

[@edwardstarrett5545]

So, a new video every day now, right?! 😏

[@CharlesHopkins]

Don’t forget to create strengthening stringers for your build. Also get an electric shear for your cutting needs. Also I agree about the sound levels. Make it more of a background and not so much in your face. Great work otherwise!! 🎉

[@jonnytoast]

Could have just screwed a pc of wood down on top instead of making a whole new "ramp" lol. Good job though. Keep it up

[@carabasi]

Me alegra mucho que estéis en España, trabajando en vuestro proyecto y disfrutando de mi país. Confío que el resultado de vuestro esfuerzo de buenos resultados.

[@pierremitham2964]

you shouldn't need to weight down the part, the vacuum will do that. you're haing problems with the curve because you are putting plastic underneath the part. Instead wax the surface of the form where the part will be and only put vacuum bacg on the top side. This will get the part to form to the curve better and the part will still come off the form.

[@jeffruoss9895]

I think Paikea, aka Young Barnacles, is in Barcelona , Shayne has alot of composite experience.

[@clydebaker1857]

I was thinking the carbon fiber you are cutting may have been sucked into your heater, and would surely short it out. FYI

[@Steve-Debs]

I have looked for left handed scissors for years and had people look at me real strange. Of course they were all right handed. Also would love a left handed egg slice, one with the angle on the end going the other way, about as rare as “ Hens Teeth “ . Have to draw a diagram,:-))))

[@lendurhenry]

Don't blame the quality of the blower while you are working with carbon. It is totally common that fibers will end up in the blower.

[@svvoyager]

Your mold is concave, would the reverse i.e. convex solve your lifting problem?

[@statewidetfd4107]

I think it's too thin still. I give it 50/50 being strong enough to hold it up.

[@DoingitWrong]

A carbon fiber sandwich!?! That’s a bold move, Cotton! You make an excellent technical work team. 👏 👏👏 I try to avoid buying electrical/electronic stuff off Amazon. I’ve been disappointed too many times with shoddy products or repackaged damaged goods.

[@Rockyman-99]

Nice soundtrack… Gamma Skies now added to my workout playlist….

[@Audra-nh6bw]

Was I the first to subscribe, the 1 popped up !!! Great Stuff !!!

[@Jccj93486]

Y’all are awesome. I haven’t commented in a while but it is awesome how well y’all work together.

[@TreasureoftheSun]

Just use wax paper where you don't want epoxy to stick.

[@hillhill9871]

Oh f yeah comment

[@danielsimms5796]

Ok, my theory is that you 2 really wanted to glass some stuff and this is the thing with the most glass work.

[@dbanks1277]

I have been dreaming of doing some stuff in carbon fiber! Thank you! we can share learning curves!

[@markwng]

Welding stainless steel is much much easier but would be boring content, so all power to you, you do make good content.

[@curtschu]

It’s possible a strand of carbon shorted the heater. Carbon is conductive

[@chipcleveland990]

I'm looking forward to seeing how it comes together..the attachment system will be interesting to see 👏👏👏

[@georgedaviau9612]

Your doing fine fiberglass is not hard.