Carbon Fiber Mountain Bike Frame Construction

Posting All CAD Files to GrabCAD

First Ride

More Bike Assembly

Partial Assembly of the Bike

Sanding the Run-Off Carbon from the Hard-Points

Removing the Printed Hardpoint Plugs From the Composite Frame

FINALLY an Acceptable Clear Top Coat for the Carbon

Yet Another Failed Attempt at a Pretty Finish

Another Fail at Applying a Clear Coat

Estimating Wall Thickness of Carbon Composite Bike Frames

Why Vacuum Bagging Is Not Ideal for Composite Bike Frame Construction

Stress Concentrations in Bicycle Frames

Epoxy Clear Coat with Severe Bubbling

Final Sanding Preparing for Clear Coat

Carbon Layer Tally and Wall Thickness Approximation

Jan 29: Fill in Gusset Void

Jan 07: Another Layup on the Frame Transitions/Junctions

Jan 01: Layup on Main Tubes

Dec 31 Layup: Head tube, Bottom Bracket, and Seat Tube to Top Tube

Sanding [again]

Dec 30 Layup: Main tubes

Ply Cutting and Hacking a Squeegee Roller

Dec 29 Layup: Head Tube Gussetting and Unwrap of 3 Layups

Cutting 45-45 Bias Plys and Clean-Up

Dec 29 Layup: Top Tube, Link Pivot, and Shock Mounts

Dec 29 Bottom Bracket Reinforcement