Ethan Clarke
Carbon fiber skinning is a technique used to cover, reinforce and upgrade existing interior plastic parts. It is a process that involves laying layers of carbon fiber fabric over existing parts using an adhesive such as resin or epoxy. This process can be done by hand or through vacuum bagging, which requires more skill and materials. When working with carbon fiber, it is important to take safety precautions as the fabric and resin can be skin irritants. It is also important to work slowly and carefully to avoid air bubbles and wrinkles in the final product.
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What You'll Learn
Prepare your plastic surface
Before laying carbon fibre over plastic, it is important to prepare the plastic surface. This process involves several steps to ensure a smooth and safe application. Firstly, it is crucial to understand the potential health hazards associated with carbon fibre and resin. Carbon fibre fabric is brittle and can break into tiny fibres that can irritate the skin, while the resin is a chemical that can cause skin problems such as dermatitis. Therefore, it is essential to take protective measures, such as wearing gloves and long sleeves, to avoid direct contact with these materials.
The next step is to ensure that the plastic surface is smooth. Most interior plastic has an embossed texture, so it needs to be smoothed out before laying the carbon cloth. This step can be labour-intensive, but it is necessary for a seamless finish. Additionally, it is important to consider the compatibility of the materials. Carbon fibre and aluminium, for example, do not work well together due to corrosion issues.
When preparing the plastic surface, it is crucial to work in a clean environment to avoid any unwanted particles adhering to the surface. Cover your work area with plastic sheeting to catch any spills or excess resin. Before applying the carbon fibre, it is recommended to do a dry run to ensure the carbon fibre sheet will lay correctly and match any existing overlays. This will help you visualise the process and make any necessary adjustments.
Once you are satisfied with the dry run, it is time to mix your resin. Epoxy resin is commonly used and should be mixed according to the manufacturer's specifications. Wear gloves during this process as the epoxy is toxic and can be absorbed through the skin. Make sure you mix enough resin for your first coat, as the carbon fibre fabric will soak up a significant amount. Then, slowly brush the resin onto the plastic surface, ensuring an even coat to avoid air bubbles.
After applying the resin, use a hairdryer on a low airflow setting to gently heat the surface. This helps to remove any remaining air bubbles by allowing them to float up and pop. Once the surface is dry, you can move on to the next step of laying the carbon fibre.
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Use gloves and protection
When laying carbon fiber over plastic, it is important to prioritize your safety and take the necessary precautions to protect yourself. Here are some detailed instructions on how to do this:
When working with carbon fiber, always wear gloves to protect your hands. The epoxy chemicals used in the process are toxic and can be absorbed through the skin, so gloves are essential. It is also recommended to wear protective clothing, such as long sleeves and closed shoes, to avoid any direct skin contact with the carbon fiber or epoxy. Safety goggles and a respirator are also crucial to protect your eyes and lungs from dust, fumes, and any chemical splashes.
Ensure that the work area is well-ventilated to prevent the buildup of toxic fumes. Open windows or doors, and if possible, set up a local air ventilator to remove dust and fumes. Keep the floor clean and dry to prevent slips and falls, and have a fire extinguisher nearby as a precaution. It is also recommended to cover any electronic equipment or PCs in the room with plastic boxes and keep them pressurized with clean air to protect them from carbon fiber dust.
Before starting the carbon fiber layup process, inspect the carbon fiber fabric for any defects or damage. Carbon fibers can easily break and produce fuzz, dust, or fly during handling, so be cautious when unpacking and processing the material. If you are cutting or trimming the carbon fiber, be aware that the fibers can cause irritation or itchiness if they come into contact with your skin. Always clean up any dust or debris promptly to maintain a safe working environment.
When mixing the epoxy, follow the manufacturer's specifications precisely. Epoxy is a chemical that requires careful handling, so avoid any contact with your skin and eyes. Use a clear plastic cup and a kitchen scale to measure the epoxy and hardener accurately. Once you have mixed the epoxy, it will start to cure, so be prepared to work quickly. Always dispose of any unused epoxy and hardener safely, following the disposal guidelines provided by the manufacturer.
By following these safety precautions and instructions, you can help ensure a safe and successful experience when laying carbon fiber over plastic.
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Apply epoxy or resin
When applying epoxy or resin, it is important to take the necessary safety precautions. Epoxy chemicals are toxic and can be absorbed through the skin, so always wear gloves. It is also recommended to wear long sleeves and use elastic bands to ensure that no fibres get onto your skin. The carbon fibre fabric and resin are skin irritants, so it is important to take the necessary precautions to avoid any contact with them.
Before applying the epoxy or resin, it is important to mix it with a hardener following the manufacturer's specifications. Use a clear plastic cup and a kitchen scale to measure the correct proportions. For the base coat, you may want to use a coloured epoxy, such as white for Texalium or black for standard CF.
When applying the epoxy or resin to the carbon fibre, use a brush to apply a thin and even coat. Make slow strokes with the brush to avoid creating air bubbles in the top coat. If you do get air bubbles, use a hair dryer on a high heat and low airflow setting to heat them up and make them float up to the surface to pop.
After applying the first coat of epoxy or resin, let it dry completely. This may take several hours, depending on the weather and the brand of resin. The goal is to have the resin adhere to the part and then hold the carbon fibre in place. If the resin is not cured enough, it will seep into the fabric and pull away from the surface, creating bubbles. To test if it is ready, touch it with a glove; if it leaves a stain, it is not ready yet.
Once the first coat of epoxy or resin is dry, you can lay the carbon fibre sheet over it. Be careful when applying the sheet, as any excess force can separate the weave. Use a paintbrush or your gloved hands to apply more resin and smooth the carbon fibre over the corners and edges of the piece.
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Lay the carbon fibre
Laying carbon fibre over plastic can be a tricky process, and it is recommended that you start on a test piece first to gain experience. It is important to wear gloves as the carbon fibre fabric and resin are skin irritants. Nitrile, vinyl and latex gloves are recommended to resist resin.
Before laying the carbon fibre, you should prepare your plastic parts for skinning. The plastic will likely need to be smoothed before laying on the carbon cloth, as most interior plastic has an embossed texture. You should also ensure that your work surface is covered by something disposable, like plastic sheeting.
When you are ready to lay the carbon fibre, you should first lay out your woven sheet of carbon fibre. Pour resin onto the bottom side of the sheet, spreading it out thinly and evenly. The resin is a powerful bonding agent and will provide structural rigidity, so it is important to treat it properly. You may want to do a dry run before applying anything to the sheet, to ensure it will lay as desired.
Once your carbon fibre sheet is layered with resin, you can lay it onto your piece of plastic. Be careful when applying the sheet, as any excess force may separate the weave. After laying the first face, you can begin working the sheet over the contours of the plastic, using a paintbrush and remaining resin to help the sheet hold itself to the plastic. You can also use your gloved hands to apply resin and smooth the carbon fibre over corners, applying light, constant pressure.
After you have laid the carbon fibre, you can use a hair dryer to remove any air bubbles. Turn it on high heat and low airflow and slowly wave it over the piece. This will cause air bubbles in the resin to float up to the surface and pop.
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Seal with a top coat
Sealing with a top coat is an important step in the carbon fibre overlaying process. After laying the carbon fibre sheet over the resin, you can apply a top coat of clear resin. This will strengthen the fabric and give it a nice 3D depth that is unique to carbon fibre.
When applying the top coat, it is important to avoid creating air bubbles. Make slow strokes with the brush, and use a hair dryer on a high heat and low airflow setting to slowly wave over the surface. This will heat up the air bubbles in the resin, making them float up to the surface and pop. You can then let the top coat dry completely, preferably overnight.
If you are using epoxy instead of resin, you will need to mix the epoxy and hardener in a clear plastic cup according to the manufacturer's specifications. It is recommended to wear gloves when dealing with epoxy, as it is toxic and can absorb through the skin.
After the top coat has dried, you can sand it to get a really good surface finish. This process can be time-consuming, as multiple coats of resin or epoxy may be required, with wet sanding in between coats. However, it is important to take your time and practice to produce quality results.
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Frequently asked questions
The plastic surface must be smoothed before laying the carbon fiber cloth. This is a labor-intensive process but is necessary to achieve the best results.
Carbon fiber fabric and resin are skin irritants. To avoid irritation, apply barrier cream to exposed skin, and wear thin vinyl gloves with heavier fabric or nitrile gloves over the top. Also, make sure to wear long sleeves, and use elastic bands to keep the sleeves snug against the base of the gloves.
First, apply resin to the plastic surface. Then, lay the carbon fiber sheet over the plastic, and use a paintbrush to smooth the sheet over the surface, applying light, constant pressure.
