Making a Carbon Fiber Door- start to finish

Composites Playlist: • Carbon Fiber and Compo...
To purchase parts or contact us: ajhartmanaero.com/
Facebook: / ajhartmanaero
Instagram: @ajhartmanaero
Recorded on GoPro 7 Black: amzn.to/2YW7B5N
Edited with Pinnacle Studio: amzn.to/30NWm11

[@denisbassom172]

You make it look so easy. Very jealous, but also inspired to try some myself.

[@MrBrinkman721]

Thanks man I found your channel a few days ago and I'm excited to see your work. Especially when u go to the wind tunnel to test. Love seeing the mustangs on the channel man keep it up dude!!!!

[@windywindy]

Always love watching you work! Truly a skilled professional!

[@imaanster322]

Very crisp, very clean, very inspiring, beautiful 👌🏾

[@alexmanning8710]

Dude is a carbon wizard! Great content!

[@Vittinable]

Great content as always AJ. Glad to see you are getting the car back (ironically, I crashed yesterday, no brakes at 125mph braking zone...). Keep it up!

[@ashishdabas00]

This process and workshop is so well organised… love it.

[@bodieshofner8566]

great video man! I really am tryna learn these skills for the stuff I own and future projects. Thanks, I hope to learn more from ya man

[@diomerjomer6097]

ilove how you do your work wish i can learn from you and all the matrials needed..God bless .

[@hasdalracing]

Nice work! Looks so easy

[@GrantOakes]

Great layup techniques!

[@WereAllThatBored]

Excellent work!

[@drrock5356]

Although nothing in my mind can take away from your epic composite work, removing the steel door beams does send shivers down my still-intact spine. What about adding a layer of aramid layer to the inside of the layup, to contain the deadly black shards, should the door ever get hit?

[@liamhollin8265]

I would like to thank you for sharing your knowledge, much appreciated👍👍👍👍👍👍👍

[@fxx-evo7414]

Really Nice job !! Just found your Channel, it will be a good inspiration source !!

[@meostars]

So as far as the part molds go, do you have a how to video demonstration? Great work. Appreciate you shared your craft with the world.

[@Futurebloodline2010]

Badass channel man. Great work

[@Slayerplayer05]

Wish I could make a Glass fender that Nice !! Great video !!

[@spragga1988]

Real nice work your badass 😎 💪 👏 👌 will be watching 👀 more of your videos live in the Virgin Islands 🇻🇮 will be trying some small stuff myself

[@alanv3185]

I want to make a project car with two hayabusa engines so having a carbon fiber body will really help me save a lot of weight. This is great!

[@martinmoreno2597]

Awesome!

[@dmorris8661]

Excellent work (2 thumbs up)

[@nelsonramos2218]

Awesome work

[@cliffjamerson3107]

Incredible bro

[@theezeelife292]

That is awesome. I want to do the same thing except the outer layer be forged carbon fiber.

[@ferrariguy8278]

Nice work. I can't imagine using this on a street car without a well engineered crash structure inside, which is probably beyond most hobbyist. But for a race car with a roll cage and inner crash structure, it's perfect. Better to save weight on fenders and hoods/trunks for a street car....

[@DIYflyer]

Amazing creations. Where do you buy the large rolls of carbon, peel ply and other materials from ?

[@tinymotogarage]

Almost like you've done that before 😜 - Amazing.

[@ratgreen]

Great video man Any reason why you drew the resin in from the bottom? I would have thought from the top, gravity would help it go faster. Just wondering if you had a reason. EDIT: Just seen your other comment, to avoid air bubbles. Nice. Also what epoxy you using ? Thanks

[@diegorcsantos]

awesome job

[@doblesentido]

Hey man! Been watching your videos for some time now! Congratulations, they are amazing! I am in the process of doing CF doors on my e30 m3 race car. I have some questions if you don’t mind! I noticed you used 2 layers, then soric, maybe LRC 1.5 and then 1 final layer for the door face, but for the frame, will 3 layers work OK for the hinges and lock? What about for the top frame window edge? Thanks in advance!

[@chesseman560]

Amazing stuff, I’m glad you’re back in business! What kind of epoxy are you using and do you recommend using regular epoxy resin for infusions?

[@ajhartmanaero]

No. You must use an epoxy specifically for the infusion process. Its much thinner than a regular hand lay epoxy.

[@fabricecrozat6722]

Nice job 🤘💪

[@Kleiminc]

So awesome

[@d1specdrifter]

your video popped up in my like videos.now a subscriber for sure.🤜🤛💪💪👍👍👍👍👍👍

[@islandboi1988]

Epic!

[@denisotto348]

Bro. I heard your podcast on 'Do it for a living'. You're a serious guy and thanks for your content.

[@ajhartmanaero]

Thanks.

[@LucasIsBusy]

awesome vid. TY. :D

[@rennex2005]

If not a race car it's high advisable to use the original inner structure and replace the skin of the door

[@gregreynolds9708]

What adhesive is that?? Great vid

[@Ridesign]

Amazing work but i have a question. How is it possible to polish your parts without applying clear coat on them? So you actually don't apply clear coat or the realease agent does the same work?

[@2k5mike]

Nice finish out the mold thoooooo

[@naturalmystics-kd9vt]

Aj good day do you epoxy resin or what kind of resin do you use thank you

[@chautrongan6183]

Thank Sir.

[@justinguarino201]

I am not seeing a mould video. Do you have one on how that is made? What is the orange stuff? PVC or some sort of abs?

[@young11984]

If i could do that i would have a few extras hanging on the wall prefitted but i cant so.....awesome watching you “do it all” vs having somebody do it for you. Sent your video of the IRS install to a friend last night, he is going to do one in a ‘97 Mustang

[@doubleT84]

True. But if you can do it whenever you want because you have molds and the material ready, why waste space with parts you maybe never need. And the molds are so specific to his race car, he can't even easily sell it if not needed (as at least the inner mold will not work for a street car).

[@CrazyCat229]

Oh man that GTR looks killer. I wish I could afford to have you do all the areo stuff on my RX7.... sigh

[@swimco61motorsports]

What are u spaying on the mold on the first layer and in between layers??

[@luismunoz8085]

How do you make the Orange molds ??

[@BlakesGarage]

Rad video!!! Hey do you have anything for a F82 BMW front splitter wise??

[@ajhartmanaero]

sort of. We can do splitters any shape/ size based off a template you provide. I did a video on that. kzbin.info/www/bejne/pIbOo3ahYrZnrrc

[@noneya96]

Were or how do I make the outside molds the orange bits you are using

[@jennyricciardiello2860]

What structural adhesive are you using?

[@johne8783]

What is the "spray" you used before laying in the Carbon?

[@amirzainol27]

Can i know, what kind of spray that u use

[@DragonEyeOfficial]

crazy video man ! i wish someday got a whole roll of carbon to cut from !! hey, what material you use as core ? keep it going mate , awesome video btw !!

[@ajhartmanaero]

I used Soric on this one. But I use several other cores depending on the part and purpose.

[@DragonEyeOfficial]

@@ajhartmanaero thx for the answer 👌🤘

[@frankmelero5511]

What adhesive did you use?

[@mohdrhaiz8146]

any video on how to make the mould

[@nashdaflash]

I love the instrumentals please can I have a Link to them

[@islandrsxboostedk2412]

Hey bro how much for a RSX carbon door, or do u sell the molds for the door.

[@WEIGHT_LOSS_Motorsport]

Great work, how long are your parts under vacuum with pump on after the resin runs through the whole part?

[@ajhartmanaero]

2-3 hours

[@robbiekyle2615]

Can you make carbon fiber doors for a 1985 bmw e30 or know anyone that can produce them?

[@Mike-dy6co]

What material do u use as core

[@aipod86]

How do you make the molds????

[@GermanTopGameTV]

Hey there, nice project. Is there any reason you infused the resin against gravity and not with gravity? I've always seen resin inlet ports on the upper side of a part and vacuum exit ports on the bottom. is there a reason you did it the other way around? does it help with resin to fiber ratio?

[@ajhartmanaero]

Air bubbles float. So generally you should have less voids and bubbles.

[@fazl-e-rabbi2951]

How to make a mold.? What are the chemicals used? Need to know the basics..

[@gayshelley2677]

I noticed you used a spray tac on the first layer of carbon, does this not leave imperfections on the surface finish. Thanks Ian.

[@ajhartmanaero]

If you went crazy with it.

[@islandboi1988]

Do you have any videos on you fiberglass mold making process? Door molds look very intricate and difficult. Suscribed to your channel for sure. 💪🏾

[@ajhartmanaero]

Unfortunately I never did a mold video. Sorry.

[@romocolan]

Please do 👍

[@jakubkopera7797]

What kind of spray do You use to glue carbon to the mold? Can You send me a link where can I buy it? You're making great vids! Thanks for all of the knowleage You share!

[@ajhartmanaero]

3m Super 77

[@incodewetrust8862]

What is park bake ?

[@402arif]

🔥

[@evanjohansen3478]

What do you use for the molds. I want to do some custom carbon to my miata. Do you also have a video for the basics and the set up you use.

[@ajhartmanaero]

Just homemade fiberglass molds. Unfortunately I never did a video of how I do molds it there are plenty out there.

[@markkraus3598]

Very nice,looks like you’ve done that before 😎. You’re using panel bond for the 2 half’s?

[@ajhartmanaero]

Yes

[@markkraus3598]

@@ajhartmanaero thanks-you have some good videos !

[@jijoealfonso2034]

How long it takes to make both doors..

[@michaelduque7652]

I have a question, What type of blade/cutting device do you use to trim the carbon with and then what grit to you sand to smooth it out

[@tbroekemeier]

Most guys use either a small die grinder with a cutoff wheel, or an oscillating cutter also called a multi-tool.

[@Captaindan7141]

Do you use a UV protective resin? I did a wet layup (no vacuum bagging) and used 2k clearcoat instead.

[@Captaindan7141]

Also, I'm in Minnesota as well, how much would a front splitter, rear diffuser and flat bottom in carbon fiber run me for my 2001 Impreza?

[@psycho3344]

What about the window?

[@nataliaabrantes82]

Boa noite, Tenho uma Brasília VW 1978 e queria fazer peças inteiras dela de fibra de carbono. Vocês por me ajudar?

[@millerchassis6119]

good idea with your oven. what temp do you bake it at.

[@ajhartmanaero]

135 F

[@DingoZed]

How difficult was it to make the mold for the inner side? That part confuses me the most.

[@ajhartmanaero]

Like any other part, just alot more corners and curves.

[@jkit3258]

Do you not alternate the orientation on the carbon plys to prevent warping/twisting during cure?

[@ajhartmanaero]

I do on the skin.

[@jonnymac8925]

Do you do custom work for people? Wondering about getting a rear fender for my Harley Davidson! I have a carbon fiber front fender and side panels, but the guy that made them isn't around anymore.

[@ajhartmanaero]

I’m a one man shop so I do not. Sorry.

[@dillonkoch72]

I want to make carbon doors for my 7th gen honda accord coupe. Is it possible to retain all my factory features like the power windows,door lock mechanism and regular door panels?

[@ajhartmanaero]

Yes. You’d just incorporate all that into the mold and lay it up strong enough to hold it all.

[@TheFarCobra]

Do you keep vacuum on all night through the bake? How do you keep the pumps cool?

[@ajhartmanaero]

Pumps are only on till it sets. So like 2 hours. Full cure is about 4 hours. I put a fan on each pump.

[@ariklotia3958]

Ok so I’m 1:11 in.. my question is did you use fiber glass to make your mold first for the doors?

[@ajhartmanaero]

Yes

[@abadibi]

what if i wanted to mold the entire inner panel? is it possible or is that pattern too complex for the carbon/resin mold making?

[@ajhartmanaero]

You could.

[@SoaringExperience]

7:07 wouldnt it be a kind of help to use gravity as a "pusher"? I mean if you put the container where you fill in the epoxy below the highest part where you wanr resin? Even without vakuum a fluid want to flow there, but with vakuum you can control it better? Just an idea, I have no experience with infusing.

[@ajhartmanaero]

You can get "balooning" which isn't good so keeping it low just prevents that even being an issue.

[@SoaringExperience]

thank you! @@ajhartmanaero

[@reallyreallypanda8969]

Any videoa on making molds? Are the molds vacuum formed?

[@ajhartmanaero]

Soon. I have a bunch of people asking about a mold video so may do fenders on the GT350 soon

[@cloane85]

Wow this is awesome! My only thing for this video is I really wanted to see weight difference. Before and After weighing I think would have added to the video in a good way, just my opinion though.

[@ajhartmanaero]

I’m just remaking a carbon door to replace a carbon door. So no steel door to weigh. But this one weighs in around 6lbs.

[@cloane85]

@@ajhartmanaero 6lbs seems so light that's legit! Thanks for sharing! That gives an idea of rougly what the weight savings is if I weighed my doors

[@huizdeeze1075]

awesomeness , what adhesive did you use to bond skin and frame together?

[@ajhartmanaero]

3M panel bond

[@huizdeeze1075]

@@ajhartmanaero 3M 08115 ?

[@ajhartmanaero]

@@huizdeeze1075 yes

[@huizdeeze1075]

@@ajhartmanaero Thanks

[@trig8364]

How much would some svx front fenders cost me 😅

[@shembooy]

💥 огонь

[@redzone5655]

Nice job! How did you solve the hinges?

[@ajhartmanaero]

Transferred from the oem door.

[@redzone5655]

@@ajhartmanaero oh thanks! What are your thoughts using a vaccum dedicated pump vs an air compressor with a venturi valve to create vaccum. Would they work the same?

[@Obs.society]

What type of core material do you use ? Or what type do you recommend?

[@ajhartmanaero]

I used soric here.

[@georgefitzpatrick1272]

I’m trying to figure out what the spray he uses is to put the carbon together, is it just spray adhesive?

[@jennyricciardiello2860]

Spray tack

[@esskettiticy5355]

What was that white core material you used and what’s it for?

[@ajhartmanaero]

Soric

[@TheMikeBeauchamp]

Is your leak detector just a tube held to your ear? Gotta try that!

[@ajhartmanaero]

Yes

[@chrisbouchard4719]

Aka a hillbilly stethoscope

[@101hotwire]

Is there any benefits for pulling vacuum vertically

[@ajhartmanaero]

yes. Air rises so less chance of air voids or bubbles. You can infuse flat, or even if part of the part goes downhill is ok, but generally you want the epoxy to go "up hill".

[@ariklotia3958]

I do have many serious questions, but idk if that’s ok to ask on this platform.. but I want to do this is the state I live in.. but I’m having a hard time finding anyone willing to teach me what I’ll need.. I’m above labor skill wise but I have the want for this and I want to turn it into a business.

[@stefanandras9382]

how much did the whole body cost to produce it from carbon fiber?

[@ajhartmanaero]

I’d cry if I actually kept track and put a value to the time making the molds.

[@vinzleow3817]

Would these be safe for a daily driven vehicle?

[@ajhartmanaero]

No