CycleKarts GB

Forums => Tech Forum => Topic started by: Mark Under on 29 November 2021, 10:14:50 pm


Title: Best Way to Build a CK Body
Post by: Mark Under on 29 November 2021, 10:14:50 pm
I have got to the stage of thinking about building the body for my Cycle Kart.

Has anyone got any experience of using GRP to make a body, I am sure I have seen someone carve a foam body out and then coat it in GRP and then removing the foam to leave the GRP body.

I'm not sure if this would work or what type of GRP etc would be used.

Thanks
Title: Re: Best Way to Build a CK Body
Post by: dunworkin on 29 November 2021, 10:55:48 pm
Im in the process of doing just that. I struggle to get photos posted on here but no problem on Facebook cyclekarts , hope this link will work. You're very welcome to come and have a look or give me a call.
GBhttps://www.facebook.com/groups/CycleKartsGB/?multi_permalinks=4262655597173091&notif_id=1638122230854973&notif_t=feedback_reaction_generic&ref=notif
Title: Re: Best Way to Build a CK Body
Post by: dunworkin on 29 November 2021, 10:59:07 pm
https://www.facebook.com/100000644251866/videos/3095799587402750/

try this one  ;D
Title: Re: Best Way to Build a CK Body
Post by: Mark Under on 30 November 2021, 07:31:34 pm
Thanks, that looks great.

When you say plaster, do you mean the stuff that you plaster walls with or is there something else.

I would be over the moon if mine turns out anywhere near as good as yours.

Title: Re: Best Way to Build a CK Body
Post by: dunworkin on 30 November 2021, 09:08:56 pm
I used bonding coat for most of the shaping, its perfect for building up the low spots. I found that the hardest thing was to get symmetry very testing ! then just ordinary plaster to get a smooth finish, this time sanding out the high spots !
I'm sure you could build that shape with aluminium if you had skill & patience, an English wheel, Tig welder and years of experience, Ive none of those, just patience, its been a long job !
Title: Re: Best Way to Build a CK Body
Post by: Seven racer on 01 December 2021, 08:35:49 am
If it's any help, I've just been working on a nosecone buck, and will be doing the tail section and cowl in a similar manner, I used a timber frame filled roughly with foam, (squirty stuff from a can). This was shaped roughly to just below finished level, then given a skim with gyproc drywall jointing plaster. It took a couple of layers to get close to final shape, but a quick spray of paint for a guide coat soon shows where any low spots are.

I prefer the drywall to plaster as it stands and shapes very easily, the downside is that it's softer, O.K. for just putting a layer of cloth on, but I wanted to make a buck, so I have ended up with a layer of tooling gel coat to give a hard shell.

This just needs a bit of spot filling and sharpening of corners and it should be ready to take a mould, it could just take glass at the finished plaster stage,  butI just decided to make things difficult for myself and make a full mould.

[attach=1]
Peter
Title: Re: Best Way to Build a CK Body
Post by: Seven racer on 01 December 2021, 08:37:31 am
Foam
Title: Re: Best Way to Build a CK Body
Post by: Seven racer on 01 December 2021, 08:38:39 am
Plaster
Title: Re: Best Way to Build a CK Body
Post by: Seven racer on 01 December 2021, 08:39:51 am
Guide coat and final sand
Title: Re: Best Way to Build a CK Body
Post by: Seven racer on 01 December 2021, 08:41:16 am
Tooling gel ready for final skim of body filler
Title: Re: Best Way to Build a CK Body
Post by: Chris L on 01 December 2021, 05:06:47 pm
Lookin Good Peter  ;D. Well done .

Chris L
Title: Re: Best Way to Build a CK Body
Post by: Mark Under on 02 December 2021, 09:57:21 pm
Peter

That looks really good, I am definitely going to try the GRP route for the body.

Mark
Title: Re: Best Way to Build a CK Body
Post by: Seven racer on 02 December 2021, 10:23:01 pm
It's not half as good as Simon's!  :)

Peter
Title: Re: Best Way to Build a CK Body
Post by: dunworkin on 06 December 2021, 11:14:38 pm
Appreciate the compliment Pete....youre not doing too bad yourself.
Nearly 50 years ago (when I was young and knew everything ) I worked in a boat yard laminating new hulls and getting the **** repair jobs. I find it hard to learn new stuff now but I'm apparently a kinesthetic learner so raking up those old skills/experience was helpful, I did forget how long things took though !
Title: Re: Best Way to Build a CK Body
Post by: Andy_B on 07 December 2021, 10:25:40 am
Not sure if it would benefit anyone but I do have a buck for a boat tail that is on my Austin if someone wanted to take a mould. I could measure it up if anyone interested.