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Composite canopy copy

Old 07-16-2017, 12:27 AM
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Default Composite canopy copy

Is there a simple way to make a composite (non translucent) canopy copy from a Lexan original ?

Can I lay fiberglass cloth directly inside or over the lexan original coated wit a release agent canopy without having to make a mold ?
Old 07-16-2017, 05:45 AM
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Yes you can, use a proper release wax to be sure you get an easy release without damaging anything. Using "twill weave" fiberglass or similar that is particular suitable for compound curves would be a lot easier than using "plain weave" that don't conform to compound curves very well. Other than that it is usually better with several thin layers perhaps at different orientation rather than one thick layer with a rough/coarse/stiff and unmanageable weave.

One thing you could do to make sure you have a backup of the canopy shape just in case anything should go wrong is to fill it with plaster first to make a plug, probably not necessary but it would make sure you can always make that exact shape again.

Last edited by ibuild; 07-16-2017 at 06:01 AM.
Old 07-16-2017, 09:21 AM
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You might search the "Composite Fabrication and Repair" thread on this forum.
Old 07-16-2017, 08:00 PM
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Super easy to do. Two examples, the first one was done using an existing canopy as a male mold. The second one was done using the original canopy as a female mold. Both were waxed and had PVA applied as a release. The layup is simply a surface layer of 1.4 oz cloth followed by two bulk layers of 3.7 oz cloth, all plain weave.
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Old 07-17-2017, 02:06 AM
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Originally Posted by speedracerntrixie
Super easy to do. Two examples, the first one was done using an existing canopy as a male mold. The second one was done using the original canopy as a female mold. Both were waxed and had PVA applied as a release. The layup is simply a surface layer of 1.4 oz cloth followed by two bulk layers of 3.7 oz cloth, all plain weave.
Thank you ! I can do that.
Did you lay one piece layers ? Any problems with the compound curves ?
Old 07-17-2017, 06:34 PM
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Yes, single peice layers, no issues with it taking shape. Use a resin with at least 1/2 hour pot life, start at the center and work your way out. Think,of the glass cloth like Monokote. It will compress some and it will relax some. There are glass fabrics that " drape" better then others such as the twill weave previously mentioned and S2 cloth also known as " crows feet " but I have found plain weave to be perfectly acceptable for non structural parts.

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