Fresh out of the mold 🥰
Works just like the original but is 100g lighter.
Self-made super stiff EPS core with 4 layers on each side:
- 275 g/m² carbon top-layer 0/90°
- 400 g/m² biax carbon ±45°
- 200 g/m² unidirectional carbon
- 240? g/m² glass fiber 0/90°
Since there have been many questions how we do the EPS foam core: It's a simple but messy process, that is also why I don't have any pictures at this point. First you have to add some material to your mold-halves that has the same thickness as the carbon fiber will have. There are special wax plates for that ranging from 0.1-3mm thickness. If you want it cheaper get some noise isolation layers for parquet floors from your do-it-yourself market with ~1.5mm thickness. After fitting those layers into your mold cover them with this elastic plastic household foil. Next, mix 1l of EPS balls with 100ml of epoxy and 100ml of microballons (of course more or less depending on the volume for you build but to get an idea of the ratios) and work them into your mold halves until you can close them with some but not too much force. I do use clamps for that. After removing the cured core from the mold trim the edges a bit and make sure that it has enough space to fit between the mold halves after you have added the carbon fiber. You should also add some epoxy-microballon mixture to fill gaps between the fiber and the core.
