: Badass Carbon Fiber Tonneau Cover, No Exposed Fasteners!!


Ultra-Carbon
08-07-2015, 01:43 AM
A few weeks ago, we started on a tonneau cover for a customer with a full custom 1963 Ford Ranchero race car/show car. I took a lot of pictures of the build, so this thread will be very picture heavy.

The customer asked for a clean, neat install on some carbon fiber panels we make. The original plan was to use dzus fasteners to hold the panels in place and install aluminum rails under the panels, screwed to the inner bed walls, which would support the tonneau panels. As the car sat at the shop a few days while we began laying up the panels, I had an idea. I'm the type of guy who always wants to challenge himself, so I decided that I'd like to try to build the angle rails out of carbon fiber and build them into the bottom side of the panels. That would enable the absolute cleanest possible install, without any exposed fasteners on top, other than the actual Aerocatch latches that lock down the hinged rear panel.

Here are the before pics........

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/CDAD9D33-88DF-474B-9EED-0482C9E5541C_zpsnlgudfmm.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/CDAD9D33-88DF-474B-9EED-0482C9E5541C_zpsnlgudfmm.jpg.html)

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/CB6DEF2B-6998-496E-B2B5-B074CAD76C39_zpsw9bj7n1f.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/CB6DEF2B-6998-496E-B2B5-B074CAD76C39_zpsw9bj7n1f.jpg.html)

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/6AA97298-8EEF-46ED-BCE3-8033AF1244E8_zpsnlpgl1lm.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/6AA97298-8EEF-46ED-BCE3-8033AF1244E8_zpsnlpgl1lm.jpg.html)

Ultra-Carbon
08-07-2015, 01:58 AM
The first step in the process was to mask off every area of the car that we thought we would have contact with.


http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/24E46FAA-D142-41AF-AA92-B9152AA3F624_zpsqp2hvv5y.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/24E46FAA-D142-41AF-AA92-B9152AA3F624_zpsqp2hvv5y.jpg.html)

After masking, we started the long, arduous task of making templates for the panels. This was especially tricky with this car for several reasons. First, the car has four roll bars, all coming in at different angles and in different places. It wouldn't have been difficult to make the tonneau in four or five pieces, but the goal was to get it done with just three pieces. That meant tucking one full piece behind all four bars. The toughest part of that, is that the rear "wings" of the b-pillars jutted out well behind the back window, unlike your typical pickup bed that has a flat back window area.

For templates, we use corrugated plastic panels. They are very similar in weight and construction to cardboard, but they are far more difficult to put a crease in, making for a material that would remain intact and rigid where typical cardboard would get bent and misshapen and folded. Making that first template took dozens of trips in and out of the car, cutting and trimming and taping, little by little. It took more than a day and a half just to get the template perfect.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/C29E30ED-8244-4512-B379-493335F86914_zpspmmajmxv.jpg[/IMG] (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/C29E30ED-8244-4512-B379-493335F86914_zpspmmajmxv.jpg.html
http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/CCF7A7FE-605F-4226-A292-298FC49974E1_zps3zw23oub.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/CCF7A7FE-605F-4226-A292-298FC49974E1_zps3zw23oub.jpg.html)

Ultra-Carbon
08-07-2015, 02:04 AM
Once we got the first template made, we were able to make the second template. This went much, much faster, only taking a few hours to complete.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/99D686C0-5630-486C-9003-B676C033E982_zps73waybhj.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/99D686C0-5630-486C-9003-B676C033E982_zps73waybhj.jpg.html)

After getting both fitted, it was determined that part of the first panel would need to be added to the second panel to make the nicest, most seamless fit.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/C7FED190-FE04-4104-9993-9C70B4ECF8AB_zpsi9mixght.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/C7FED190-FE04-4104-9993-9C70B4ECF8AB_zpsi9mixght.jpg.html)

Here is the finished first template piece.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/8B7EB231-1393-4FBF-98A7-95EE553D9AD0_zpssk5f0nhl.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/8B7EB231-1393-4FBF-98A7-95EE553D9AD0_zpssk5f0nhl.jpg.html)

Ultra-Carbon
08-07-2015, 02:20 AM
It is important to understand that these templates have to be exactly nuts-on because I need to use the templates to determine where the reinforcing core material goes, as well as determining where the reinforcing angles go on the edges to fasten those panels to the bed sides. One small mistake or miscalculation in these templates, or not copying them exactly to the carbon, would result in the carbon panels not fitting right, or not fitting at all. Then we would be back to square one, starting over.

So, here we have the reinforcing foam core that goes between the layers of carbon fiber. Essentially, we took the templates we made and just subtracted 1/4" all the way around the perimeter and around the bars so that we wouldn't have any exposed white foam sticking out from the cuts when we trim out the carbon fiber. We laid up both pieces on the table as they will sit on the car, so the carbon weave has a consistent, continuous look, helping to make the two panels blend more like one.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/CC00D6BF-CEFE-4475-A31A-B7A3897AE6BD_zpsvpr8ea2p.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/CC00D6BF-CEFE-4475-A31A-B7A3897AE6BD_zpsvpr8ea2p.jpg.html)

Here is the resin spreading from one end of the part to the other. This process of dry layup and adding resin while under vacuum is called "resin infusion" or "vacuum infusion". It is a very good method for creating top quality parts, with great strength and very little excess resin.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/87D02711-8E72-4B6A-B66A-1683A8334074_zpsftjczebm.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/87D02711-8E72-4B6A-B66A-1683A8334074_zpsftjczebm.jpg.html)

Here is what that carbon looks like after all the infusion consumables are stripped off and the finished carbon fiber part is exposed. This is the bottom side, which is why it has a rough, matte finish. The other side, which is against a glass table top, is the high gloss side.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/47835939-92C0-4849-8E21-A8864C585639_zpsdaoisqbj.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/47835939-92C0-4849-8E21-A8864C585639_zpsdaoisqbj.jpg.html)

Ultra-Carbon
08-07-2015, 02:27 AM
Now for the flanges. These are built to resemble add reinforcing strength to the edges and a flange to screw to the inside of the bed walls.

We built up an MDF and 2x4 backer to lay the carbon up against, all the way around the perimeter of the two pieces together. 3M metal tape covers the entire framework so the resin and carbon doesn't stick to it.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/931BA8B9-073E-412C-99F5-E62F9CEEE607_zps3qbsuhpz.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/931BA8B9-073E-412C-99F5-E62F9CEEE607_zps3qbsuhpz.jpg.html)

The framework is now added to the table and taped down, then a secondary bag is sealed up against the outside to keep the resin from spreading outside the working area onto the finished area.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/9A486B66-F998-4E8B-86F3-2892353096E3_zpsyl88mdjt.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/9A486B66-F998-4E8B-86F3-2892353096E3_zpsyl88mdjt.jpg.html)

Here's the entire structure just before adding resin.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/D0577B45-D805-4DD1-AB7D-B520677A8FB7_zpsxqqtdzvc.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/D0577B45-D805-4DD1-AB7D-B520677A8FB7_zpsxqqtdzvc.jpg.html)

Ultra-Carbon
08-07-2015, 02:32 AM
And here is the final result of that entire day worth of work. It didn't turn out nearly as perfect as I had envisioned, but it looks exactly like I needed it to look.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/03CE52B4-AC7A-4997-9DD1-9B3A26F8C8B5_zpsn0e6b6wt.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/03CE52B4-AC7A-4997-9DD1-9B3A26F8C8B5_zpsn0e6b6wt.jpg.html)


Here is what the bottom side of those two panels looks like after applying a gloss coat of epoxy and after trimming and fitting them.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/09D15363-3047-4630-B950-3EDCADEF5ACD_zpsp2vs0c3x.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/09D15363-3047-4630-B950-3EDCADEF5ACD_zpsp2vs0c3x.jpg.html)

Ultra-Carbon
08-07-2015, 02:49 AM
Now with the pieces fully masked off, it's time to begin cutting and trimming and fitting them. This took almost two days for the first panel because we had to be extremely careful moving the panel in and out under the bars so as not to scratch the paint on the car and the roll bars. And keep in mind that one small mistake, one slip-up, one scratch to the car or the panel, one little jump of the jig saw, or one stray jab, and the part is garbage and we start over. We're in the home stretch, but cutting carbon fiber is painstaking slow because of all that. Way, way worse than trimming out some hood or trunk lid.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/53BD2285-DE73-4383-8873-6200C42EA1AF_zpseej3gljh.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/53BD2285-DE73-4383-8873-6200C42EA1AF_zpseej3gljh.jpg.html)

Second piece trimmed and fit.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/B8881307-C760-4FE8-9756-B8350C3513AD_zpsauob6vq8.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/B8881307-C760-4FE8-9756-B8350C3513AD_zpsauob6vq8.jpg.html)

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/A5F3E892-8E4D-4FA1-B0E5-B3A6B67EC85D_zpsur30t70q.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/A5F3E892-8E4D-4FA1-B0E5-B3A6B67EC85D_zpsur30t70q.jpg.html)

Ultra-Carbon
08-07-2015, 02:53 AM
Now that both panels are fitted, it's time to mask off the bottom of both panels and epoxy the locking tabs in place. Remove them carefully one last time, apply tabs, then remove masking and install for the last time.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/22B61694-008D-44C3-9B90-E6B316348AE1_zpshu83re8n.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/22B61694-008D-44C3-9B90-E6B316348AE1_zpshu83re8n.jpg.html)


http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/453A80A8-64A7-465E-A0AB-3FBEBCAEBE83_zpsa7fbgern.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/453A80A8-64A7-465E-A0AB-3FBEBCAEBE83_zpsa7fbgern.jpg.html)

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/F862A583-368C-4907-9AAB-4EDFB58CFEEA_zpsfwsn3sq1.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/F862A583-368C-4907-9AAB-4EDFB58CFEEA_zpsfwsn3sq1.jpg.html)

Ultra-Carbon
08-07-2015, 02:56 AM
Now the reinstall. All fasteners, including the piano hinge, are stainless steel.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/DD546695-3D21-4624-99F0-B5A39B21162C_zpsn4ni8otw.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/DD546695-3D21-4624-99F0-B5A39B21162C_zpsn4ni8otw.jpg.html)

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/0DA4317A-8FD5-45DF-B47E-040FC6F86F89_zpsrde8qs1l.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/0DA4317A-8FD5-45DF-B47E-040FC6F86F89_zpsrde8qs1l.jpg.html)

Summertime and installing these panels in the dark at 1am. Glad I've got good lighting....

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/BD4E2FA5-B6E4-4A39-87E7-4482F83C83AD_zpsdrt6mhse.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/BD4E2FA5-B6E4-4A39-87E7-4482F83C83AD_zpsdrt6mhse.jpg.html)

Ultra-Carbon
08-07-2015, 03:01 AM
Some side shots....

Keep in mind that these pieces are now fully installed. No exposed fasteners and no fasteners to connect the joint where the two panels meet!


http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/CEEB1284-88B1-4132-BB6F-4275D4AC6649_zpsalm8prgp.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/CEEB1284-88B1-4132-BB6F-4275D4AC6649_zpsalm8prgp.jpg.html)

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/B317A58E-99C6-434B-8A59-85FC7CD8255F_zpsugzyf5zz.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/B317A58E-99C6-434B-8A59-85FC7CD8255F_zpsugzyf5zz.jpg.html)

Ultra-Carbon
08-07-2015, 03:18 AM
Compared to those last two panels, the hinged panel is pretty boring. The only real challenge was that the bed rails at the back of the car go in an upward direction. So, we had to decide if we wanted the last panel to be flush with the bed rails and tail up, or continue use it flat with the rest of the panels and have the back side fit lower to the eye at the back. We chose the latter, for an overall smooth, flat look.

First, we fit it with masking tape applied.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/A5E379C3-655E-4753-A2C0-F53CF66663BF_zpsjjd6hpdk.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/A5E379C3-655E-4753-A2C0-F53CF66663BF_zpsjjd6hpdk.jpg.html)

Next, we installed an aluminum angle rail to fasten the pins for the Aerocatch fasteners. I had planned to do this part out of carbon also, but we were already way behind schedule with all the extra work that I had added to the job. The customer was anxious to pick up his car and I couldn't add another couple days to the job just for this one little piece.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/9CEC894E-9DCC-45DE-B091-76DAB2FEA1F1_zpsghj875ux.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/9CEC894E-9DCC-45DE-B091-76DAB2FEA1F1_zpsghj875ux.jpg.html)

The underside of the hinged panel. Note the stud on the underside of the panel connecting it to the hinge. We epoxied bolts to the bottom side of the carbon panel to hold the hinge on to keep with our theme of no exposed fasteners. Just another one of those touches we added that had to be figured out how we would do it long before we built a single carbon part.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/EA11E7F8-C5B7-4A1B-A3FD-1F75FD1ABDB2_zpseer8vxgl.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/EA11E7F8-C5B7-4A1B-A3FD-1F75FD1ABDB2_zpseer8vxgl.jpg.html)

Ultra-Carbon
08-07-2015, 03:22 AM
And finally, the finished tonneau. Weighing in at under 25 pounds for the entire system, including the stainless hinge, angle aluminum, and all fasteners, we kept this car lightweight while reducing the drag and turbulence of the open bed.

And one other thing, we designed it so the tailgate could be opened and closed without opening the tonneau.

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/3D69A607-8B7A-4C3C-A605-7F54731B4468_zps7sk2iebd.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/3D69A607-8B7A-4C3C-A605-7F54731B4468_zps7sk2iebd.jpg.html)

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/13865ABA-62CB-4E02-9299-FD9BA8B9AD96_zpsnxqjgkko.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/13865ABA-62CB-4E02-9299-FD9BA8B9AD96_zpsnxqjgkko.jpg.html)

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/A6818ABE-39EC-4F9A-AE13-A2A00D338AC5_zps9mwlbusa.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/A6818ABE-39EC-4F9A-AE13-A2A00D338AC5_zps9mwlbusa.jpg.html)

Ultra-Carbon
08-07-2015, 03:27 AM
We even had enough material left over to make a couple of door panels for the car.......

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/4D235A4E-411B-4F8D-B0A1-AFDEB29EB61E_zpsuxow5ni0.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/4D235A4E-411B-4F8D-B0A1-AFDEB29EB61E_zpsuxow5ni0.jpg.html)

And lastly, the finishing touch telling everyone who did the work......

http://i72.photobucket.com/albums/i173/fun2xlr8/Customer%20Cars/BrentFromYakima/B874E5D6-A881-4DCC-B48E-C6298D74683A_zpscerxq25i.jpg (http://s72.photobucket.com/user/fun2xlr8/media/Customer%20Cars/BrentFromYakima/B874E5D6-A881-4DCC-B48E-C6298D74683A_zpscerxq25i.jpg.html)











The end.

Baddak
08-07-2015, 04:14 AM
Thats some baddass work good job guys. :supz:

Turbo 70 Camaro
08-07-2015, 01:37 PM
Damn that's cool

zmg00camaross
08-07-2015, 01:48 PM
Awesome work.

boostedbowtie
08-07-2015, 03:36 PM
SHOW OFF .

TerryH
08-07-2015, 03:39 PM
There's just a ridiculous amount of bad ass in those pictures!!! Nice work!

Rich_1028
08-07-2015, 03:43 PM
very cool!
and prolly $$$

intocarss
08-07-2015, 04:16 PM
Very nice work!!!!!!!!!!!!!!!!!

Ultra-Carbon
08-07-2015, 04:23 PM
Thanks everyone for the compliments. It was a lot of work, but I'm very happy with the results.

94Yellowbird
08-07-2015, 04:33 PM
Very nice finished product!!

LarryO
08-07-2015, 04:56 PM
shit, I wish I could wheel my car down there and get it the Ultra Carbon treatment.

bondo92
08-07-2015, 05:06 PM
That is some awesome craftsmanship, be proud !!!

Wicked Fast
08-07-2015, 05:07 PM
Clean!

Ultra-Carbon
08-07-2015, 06:54 PM
Thanks guys!

Joe_K
08-07-2015, 07:37 PM
Thanks guys!

You're a talented MoFo!!

NoBars
08-07-2015, 08:30 PM
What do you recommend to epoxy the locking tabs on? I have a carbon rear seat delete that I need to add a couple strips to to fasten the panels together and finish off.

Ultra-Carbon
08-07-2015, 08:48 PM
What do you recommend to epoxy the locking tabs on? I have a carbon rear seat delete that I need to add a couple strips to to fasten the panels together and finish off.

I use two different types of epoxy. If you need something to set up quickly, then I recommend Plexus MA300. It sets up in five minutes, but generates a LOT of heat. It gets hot enough to warp a panel if you aren't careful. For something you can set and clamp and let it dry overnight, I like 3M panel bond. It's about double the price of the Plexus, but it's much gentler on parts. It also says quite a bit more than the Plexus, so you may need to build a dam to keep it from running. The 3M can be gotten at just about any body supply place. The Plexus can be gotten at hobby stores or RJ Racecars website in the composites section. Both types require a special the use of a special applicator gun and mixing tubes, but that's what any high grade, two-part epoxy is going to need.

05MoneyPit
08-07-2015, 09:01 PM
As always your work is bad ass.

Lee

frank zappa
08-07-2015, 09:25 PM
I couldn't afford the blue tape on that job . dammmmm nice work !!!!!

Ultra-Carbon
08-07-2015, 09:37 PM
I think we probably went through at least three rolls of 2" blue tape.

Badbascom
08-07-2015, 09:51 PM
Sexy, thanks for all the behind the scenes stuff. Looks like a lot of opportunities to screw up, must be nerve racking, maybe not for you but I would be on my 5th or 6th trial by now with a dumpster full of carbon fiber tonneau covers.

Ultra-Carbon
08-07-2015, 10:35 PM
Still nerve racking for me. I've thrown away a lot of carbon fiber parts over the years. Luckily, no carbon fiber was ruined on this project.

coyote52
08-08-2015, 12:16 PM
Still nerve racking for me. I've thrown away a lot of carbon fiber parts over the years. Luckily, no carbon fiber was ruined on this project.

Most people probably can't appreciate the work that you put into your parts. Myself, (after "trying" to make some parts) can really see the time, patience and skill that you have.

Ultra-Carbon
08-08-2015, 01:43 PM
Most people probably can't appreciate the work that you put into your parts. Myself, (after "trying" to make some parts) can really see the time, patience and skill that you have.

Thanks!!

z289sec
08-08-2015, 01:50 PM
Awesome job Greg, I can't even fathom how much time there was in actually pulling that off.

Bigtruckdrivah
08-08-2015, 01:50 PM
That's nice.

Ultra-Carbon
08-08-2015, 03:16 PM
Awesome job Greg, I can't even fathom how much time there was in actually pulling that off.

I didn't really keep detailed notes on it, but I think it was about 70 hours or so, including the layup time of the carbon sheets.

That's nice.

Thanks!

425ci
08-08-2015, 03:38 PM
Great job as always Greg . Your one of the best in the business .

Seattle_Mike
08-08-2015, 03:45 PM
Beautiful work & product...hopefully people can appreciate all the work, skill, time, & materials costs required to turn out something like this.

Thanks for sharing all the pix of the process along the way, very interesting indeed.

NoBars
08-08-2015, 05:46 PM
Thanks Mr Ultra Carbon guy.

I have some 3m panel adhesive from another project, that's what I will go with.

raidmagic
12-20-2015, 11:22 AM
Great work on the front 2 pieces, the rear really lets the whole thing down in my opinion. Everything else being flush and that being under the outside lip looks funky to me. Nice piece over all though.

Yes I know this is months old.

dragula426
12-20-2015, 11:28 AM
Wow....I want one....

Beyond
12-20-2015, 12:40 PM
Nice work Greg, those bars looked like there were going to be a pain. I like how you ended up doing them.
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VT-565
12-21-2015, 04:31 AM
Looks fucken cool....any nervous moments while vacuuming the resin through the carbon?

SickSilverado
06-07-2016, 08:17 PM
That was awesome. Nice work buddy. I've been checking out your work a lot lately since I'm gonna try to tackle a fiberglass job myself. I got an oddball combo and been burned by a few shops lately, so I'm gonna give it a go.

RacerVX54
06-08-2016, 08:57 AM
WOW NICE work...

JL Performance
08-16-2016, 05:59 PM
Killer nice work!

Anyone ever talk to you about making a carbon fiber replacement panel that would take the place of the glass in a 4th gen f body, so that you could still take the t tops in and out like normal, with factory seals and whatnot on them?

It's a thought myself and a couple other guys have had for a while, nice way to pull some weight but still be able to take the tops out if you wanted to for a cruise here and there (not that I will ever likely do that with my pos but still ).

Might fit the street car market nicely.

app01
08-18-2016, 08:33 AM
I love it. very cool. Thanks for sharing.

738drvr
10-21-2016, 02:55 PM
Ok, I'll ask the obvious question...

How much?

68 nova 10.5
11-12-2016, 01:34 PM
I seen your carbon fiber parts you did for my buddies 65 chevelle ...........awesome finish almost a shame to paint them !!!!!!!!!!!!!