View Full Version : Carbon Fibre Wrapping Project v2.0

08-01-2010, 01:54 PM
Some 11,000 of you (well maybe a few of you visited more than once :excited:) took the time to visit my previous Carbon Fibre Wrapping Project thread: http://forum.e46fanatics.com/showthread.php?t=764002&highlight= or the one on Max

Well, this weekend I'm starting more challenging parts to wrap:

1. Centre Console
2. ECU Cover
3. Centre trim for e30 (for a friend)

Couldn't done the Centre Console and ECU cover (trust me, the CPU cover is version 2; version 1 was a disaster IMO :banghead:) without some changes to the materials I had used previously and some tricks learned along the way.


- West System 105 Epoxy Resin & 206 Slow Hardener FTW!!! :thumbsup:
- Dupont SelectClear 2K Clearcoat and Dupont SelectActivator 2K ;)

I've watched a ton of videos to expand my knowledge and improve my techniques (I WANT PERFECTION!!). Here are two recent videos that have had a significant impact to the way I'm preparing and applying resins and (will be finishing) clearcoats

West Systems Training Videos:

Dispensing & Mixing: (just to ensure I'm working their products properly) :read:

Applying Fabrics: Valuable Lesson here..... They use a plastic applicator to smooth out excess resin and it has made a HUGE improvement in the application (virtually no sanding its sooo level after it dries) :craig:

One major difference you need to do is apply the resin (using a small brush is fine) to the part to be wrapped BEFORE applying carbon fibre cloth!! The CF cloth MUST be "tacked" into place using the base resin before attempting to apply an initial top coat, or your weave will wander more than your bimmer with ****ed FCABs :rofl: I've taken the West System training video; combined with the video I initally used from Carbon Mods in the UK

Add some experience and experimenting (there's a couple of pieces that died a horrible death; used and abused for scientific purposes :excited: :4ngie:)

The 206 slow hardner several advantages over previous resins I've used:
- Longer pot time (the pot time is the amount of time it remains usable while in the mixing container; before being applied to part/cloth). This mixture has a pot time of 20 - 25 (my previous had a pot life of less than 5 min)
- Slow Hardening as the name implies. 90 - 110 min depending on temp


This allowed me time to carefully apply the cloth and work it into the corners, over edges, and secure it in place in those "trouble areas"... Think the results speak for themselves

Finishing Techniquea for Clearcoat:

Going to be applying this lesson to these parts and see how BEAUTIFUL they will be when done. :D

I've gotten to applying final coats of resin to the ECU cover and e30 trim. Going to me applying the final coat of resin to the centre console after posting this... :D

West sanding tonight.... :excited:

Here are some the pics so far:


After base coat ONLY (no top coat yet)

Second coat; not trimmed yet:

Second coat; trimmed but NOT sanded yet (notice the resin is virtually flat and has very few imperfections):


08-01-2010, 01:54 PM
Sanded and ready for final resin coat:

Now for the e30 Trim:


Base Coat and CF cloth; not trimmed:

2nd coat; NOT trimmed:

Test Fitting (trimmed; rough sanded):

Final Resin:

ECU Pics next posting:

08-01-2010, 01:55 PM
Carbon Fibre Wrapping Project v2.0 (cont'd).

Now some ECU pics.... If some of you saw my first post, the ECU cover was cleverly photo'd to miss several horrific (in my opinion) flaws and once this piece is done, the first is destined to become a test lab piece (no animals will be harmed during testing) :rofl:

The previous resin cured WAY TOO fast to be useful for anything but simple pieces (interior trim) because it's pot life was about 5 min and it's working life was around 10min. Reducing hardner helped only marginally as you could easily get to the point it would never completely harden. PITA!!!! :ben:

Love the West System products!!! :woot:

Here's the pictures as it progresses from stock to very cool....

BTW: The swirl of the weave next to the Lock and EMERG light is intensional. Wanted add a little weave (experimenting) and I like it..... Using one piece to cover console was the only way but created unique challenges: How to create dip for Emegency brake and where to place seam. One piece means there has to be a seam somewhere...... I put it back left corner....Tried to line-up weaves best I could.... In need of a little refining, but who gives a ****; I won't be looking @ it anyway.... and usually passangers in the rear seats are hanging on staring @ speedometer.... :excited:

About to apply final resin after posting (as I mentioned earlier), so that's where we're @ on it!!






Wet sanding tonight!! :excited: :thumbsup: and then Clear coat.....

Final buffing of Clearcoat tonight as per posted video in previous post...


Gonna be wrapping a complete set when the red fabric arrives next week. Think my interior CF set has just become 9 pieces!!!! :thumbsup:

08-01-2010, 02:08 PM
The Arsenol:


08-01-2010, 03:09 PM
Learned a real cool trick to align cloth while on roll. Take piece and lay on SMOOTH, non-porous surface. Take the leading edge and "square piece" as best as you can by eye.

Once you do that, take an exacto and cut a thread just inside the binding thread on one side. Get someone to hold other side and cut a couple of threads on what appears to be the same line as the cut on the other side. While your "assistant" is holding the opposing side, pull the single thread. It pull across the whole piece creating a blank where the missing thread is. Attach some painters tape to that straight edge and it will keep it straight and allow for even dispensing of the cloth from the roller. If you're starting with crooked threads, it makes it tough to make a good piece... This ensures the cloth is "straight" when dispensing..... Use a similar method around intended piece to keep cloth intact and it also allows you to correct bad threads (that trick you're gonna have to learn with practice)...

08-01-2010, 08:38 PM

I can see the sign above your garage...

"Nachos23 Custom Carbon Fibre Shop"

Good job....

08-01-2010, 08:46 PM
Ya, something like that. :D

Any graphic designers out there, I could use some help with a logo (got some ideas) Maybe in return for some wrapping? *th-up*

08-02-2010, 03:39 PM
Quick Update. Parts clear coated and waiting to dry. My clear coat recommends 2 wet coats with 5-10 min between for flashing.

Here are a couple of pics.




I know the weave on the inside of the emergency brake is messed, but I know what I've got to do differently when I redo with the new red CF cloth next weekend hopefully, but it sounds like I'm going to have plenty to do next weekend, so we'll see. Rest of part has decent even weaves unless I deliverately pulled them together like top left where I wanted the sweeping look for that section. Next time going to have help when applying cloth to hold parts off part and to assist with placement... That'll fix the weave issue!!

Final Sanding with 1500 + 2000 and polishing compound tomorrow; then DONE!

08-02-2010, 06:02 PM
You have a hardon for Carbon Fiber :P

Next step is to actually make Carbon Fiber parts. Then I'd be interested!

08-02-2010, 11:13 PM
You have a hardon for Carbon Fiber :P

Next step is to actually make Carbon Fiber parts. Then I'd be interested!

Not really..... Had a hardon to change my woodgrain interior after starting to mod.... tried different trim, painting, a couple of different CF products (embedded and vinyl :puke:) before almost reluctantly realizing I had to go to real CF.... *rockout* if I was to be happy.... But's been 30 yrs (longer than many members have graced this planet earth) since I last wrapped in fibreglass, so I basically had to teach myself from scratch.....

Now I've gotten to the point I want to wrap stuff that normally isn't found commercially wrapped (uniqueness) and that far more complex than the usual. Make take 1 or 2 tries to get it right and thanks to my parters/supporters I get a chance to make mistakes.....

I'm really trying to perfect the art of wrapping (its so funny remembering the early sets as I experiemented and learned... still learning; always learning).... Wife likes it too; always knows where to find me..... :facepalm: In the garage wrapping. My RC Heli hobby has pretty much died (too bad cause it's a BLAST). gonna have to find time for it....

First time attempting something as complex as the centre consoles. My first attempt @ the ECU cover did not work as well as I'd hoped (but as well as expected considering the resin and clearcoat I was using @ the time). The resin set too quickly to do anything but simple parts. West System products are great and allow me the working time (90 - 110 minutes) to wrap more involved parts.

Here are some final pictures of the centre console and ECU cover now that the clear coat has dried and ready for installation. What appear to be imprefections on surface are reflections (no matter what angle I tried, there were reflections; guess it must be smooth )





As I said previously interior weave by e-brake is messed up in a funky (kinda like the randomness way), but I know what to do when I do a new centre console in the red/black kevlar and CF cloth that will be arriving this week. Going to wrap a complete interior set including centre console for my car..... guess I'm gonna have to find a home for my current set...... :thanks:

Going to give them tonight to fully harden and install tomorrow. :str8pimpi

CF Moulded parts??? They're next on the agenda. Need a vacuum bagging system first, then I can create moulds.... Maybe a NACHOSRacing Lip for e46 sedans??? *rockout* :D :cool: This way I'll get one that FITS PROPERLY!!

08-03-2010, 06:05 AM
I'll be contacting you about the center console. Great job BTW.


08-03-2010, 01:46 PM
I'll be contacting you about the center console. Great job BTW.


Thx!! It's a PITA to wrap.... I used a single piece of cloth to wrap to maintain weave.....

Got the centre console installed last night. Had to wait till today to take pictures. Here they are:





Cloth arrived today (of course I was @ meeting so I missed delivery; picking up tomorrow)!! Can't wait to wrap set in red/black kevlar/cF cloth. Should add some nice contrast to interior. *rockout* *th-up*

08-03-2010, 04:01 PM
so clean,

did you ever take pictures of what it looked like vinyled?

08-03-2010, 04:21 PM
never made it onto the car, in fact barely made it off roll. Test wrapped one small piece, hated it and returned rolls for refund!

Posted the original embedded CF in the polymer with 3M tape (which required massive heating to bend around even simple corners.... but it too didn't look "real" you could tell it was "stuck on". That's what lead to the move to CF cloth....

08-03-2010, 05:04 PM
Was it the 3M Di-Noc vinyl?

08-03-2010, 05:20 PM
not sure the exact name I bought.

08-06-2010, 09:56 AM
I think I've managed to get Redlinegoods (www.redlinegoods.com) to make a custom shift boot to match the new red CF interior I will be wrapping this weekend. If it looks as good as I suspect, I'm going to have to sell my current set next week!! anyone interested in a complete 9 piece set? includes all standard interior trim and centre console....

08-09-2010, 12:45 PM
Well, as I mentioned earlier, was getting bored with my black CF set (wanted to make interior stand out).... and so I've started wrapping a set in red Kevlar/black CF cloth. Thought it would look good, but OMG!! :excited: it looks awesome!! :thumbsup:

These pics have a base coat and first top coat of resin. Need to lightly sand next and then 1 to 2 more coats of resin before wet sanding (tomorrow night). Just did the 4 pieces intially, but now convinced I'm doing the door trim and centre console too!!







08-09-2010, 02:04 PM
oh snap, looking good

08-10-2010, 09:06 PM
Good doesn't quite describe them. Wait till I finish the complete set and show up @ one of the meets. You'll be saying stuff like those are ****ING awesome!!! *rockout*

09-19-2010, 11:43 PM
Time for a quick update. Been investing a lot of time and $$$ to complete my air delivery system for clear coating.

Bought a new 60 gallon compressor that puts out 18.5cfm @ 100 psi; my HVLP paint guns require 13cfm @ 43psi; so lots of head room now!!! Finally got my new compressor up and running. Took a few days as I need to run the wiring 220V 30A and then service the unit before operating (been sitting for a while; so just wanted to make sure).... but here she is ready to go:


Also, recently purchased a new air filtration unit for the painting as well. Developed for Commercial Automotive painting and actually certified for hospital use (it's that good!!) Cost a few bucks, but the 3 stage filtation will ensure clean, dry, water and oil-free air to my gun.... filters matter down to 0.01 micron and is HEPA 4 certified.. *rockout* *wiggle*


Just in time too. My new set's been waiting to get clear coated for a week now and I have 3 other sets to complete (2 require clear coating to finish as well)..... Sounds like it's going to be a busy winter (lots of long shopping lists have been sent), so going to need the capacity.... LOL

Nice seeing some of you @ Bimmercruise today; sorry my new trim wasn't installed, it was waiting for all this to be completed.....

09-25-2010, 03:18 AM
First pictures of the parts for my car and a video link (please note posting time and the fact that I was "feeling no pain" when recording video.....:woot: :dave: :smokin:









Installed pictures tomorrow and who knows, maybe another video.... we'll see....

09-25-2010, 04:33 PM
For those wondering about the music in the previous video; was into the classic rock last night...... :smokin:

Might of heard hip-hop, house, fusion, reggae, or alternative rock.... 8.000 songs on iPod..... LOL :excited:

Just uploaded installed pics and holy shit :wow: am I glad I did it.... but I'll let you guys be the judge of that.... :harv:









Going to order the custom standard shift boot tonight.... going to look like this....



09-25-2010, 07:29 PM
Looks good. Your going to be a busy guy this winter. LOL

09-26-2010, 01:22 AM
YUP!!!! @ least it appears that way @ the moment. You better get that rear deck over here soon.... Gary's got some tricks up his sleeve for this winter and I'm involved, so, you'll be needing a few items done to correct that "boring" interior on such a spectacular car!!!

Need to find me a supercharger now!!! Gonna give this puppy M3 power and with AWD and the other suspenstion mods; watch out and kiss my ass good bye in the corners!!!!

09-28-2010, 07:27 PM
Going to experimenting with a couple new cloths to see how they look wrapped. I think the blue kevlar (pictured below) will look awesome as will the blue, white and black cloth.



or maybe some of this????



09-29-2010, 12:57 AM
The blue will set a few rides apart.

09-29-2010, 01:01 AM
blue white and black will look amazing. wow,

so many options now.

09-29-2010, 09:36 AM
blue white and black will look amazing. wow,

so many options now.

So many options is the idea>>> When are you bring that shift knob up so we can finish it? Or maybe we can meet somewhere..... Let me know.

09-29-2010, 10:40 AM
well i have another plain shift knob now.

maybe ill wait for you to bring in the new stuff

09-29-2010, 11:00 AM
Hey i have the best thing you could wrap in c/f!! Ya know how us bimmer folk have a issue with sagging headliners? well do a headliner!!! i will donate mine if ya wanna try it out

09-29-2010, 11:56 AM
what colour are you interested in? What did you do with the first one?

09-29-2010, 11:57 AM
Hey i have the best thing you could wrap in c/f!! Ya know how us bimmer folk have a issue with sagging headliners? well do a headliner!!! i will donate mine if ya wanna try it out

That one I'd have to think about...... Would have to build frame to support headliner because once the resin and cf is added, there's no bending the parts..... actually over that distance, there would likely be some flexibility either way. It would be cool though!!!

09-29-2010, 02:12 PM
Let me know what you think if your willing to take the challange lol i only have one headliner which is in my car but sagging really bad

09-29-2010, 02:49 PM
Im willing and trust you if ya wanna do a headliner, please let me know what colors you have available and when you are free to do some wrapping

09-29-2010, 03:25 PM
I didnt do anything with the original one,

I just had another oem one that the leather is ripping on. maybe ill get you to do the black,white,blue.

09-29-2010, 06:30 PM
Im willing and trust you if ya wanna do a headliner, please let me know what colors you have available and when you are free to do some wrapping

Well, if you want to hook up and I can check it out. My concern is that they need bend somewhat to install from what I recall. If that is the case, how we re-install? Also, do you have a sunroof?

Where R U located??? Maybe we could hook-up and take a better look @ it...... msg me through BBM Max group and we can work out details.... you're West-end right?

09-29-2010, 06:35 PM
I didnt do anything with the original one,

I just had another oem one that the leather is ripping on. maybe ill get you to do the black,white,blue.

What colour is your interior and exterior? that will help determine which colour combinations would work best for your car.....

Give me a shout and we can talk..... Too bad, I was @ Simplycars today.... we could have hooked-up.... George will also be carrying the e36 parts (trying to get him some stock now).... Trim between vents, fusebox cover from engine and centre console are parts that will be initially available..... still working on colours, but I think the standard black cf, red kevlar and blue kevlar are the likely candidates....

10-03-2010, 12:24 AM
Placed my next order for fabric;

Here's samples of what's arriving this week:

Black Carbon Fibre; 2x2 twill, 3K density:

Red Kevlar/Black Carbon Fibre; 2x2 twill, 3K density....

Blue Kevlar/Black Carbon Fibre; 2x2 twill, 3K density....

Looking forward to wrapping in the blue. Think it will look amazing in the right car...... Who's going to be the first?

10-03-2010, 02:29 PM
Just starting a new set for e46 sedan..... Need to decide whether to go black cf, red kevlar, or the new blue kevlar that's on order...... Then gonna be selling it when done....

10-03-2010, 06:17 PM
hey send me a pm i can give you details on how to get a hold of me

10-04-2010, 12:31 AM
Not sure about the headliner bud.....How the hell are you gonna get it back in after it's wrapped?? It needs to flex to get into car and be installed if I recall correctly; not an easy task wrapped in cf.... Also, I would need to figure out how to keep it's shape when wrapping it, cause if it deforms, the cf will form to that shape and be a bugger to fix..... Any thoughts or suggestions.... I'm up for the challenge if I we can figure out these points; cause wrapping something that comes out shit, sorta defeats the purpose.... PM sent though.....

10-08-2010, 09:55 PM
would the headliner be do-able if the windshield was out of the car??

10-10-2010, 12:57 AM
would the headliner be do-able if the windshield was out of the car??

REALLY NOT SURE if the headlner is doable @ all..... Way too much "normal" suff on the go to try and get into a project that for all intensive purposes has a better failure rate than likely sucess rate. We are really asking for trouble trying that piece.

Let's get those seats done first and we can go from there..

10-10-2010, 01:57 PM
Received my new shift + e-brake boots and armrest cover.... Got the shifter boot installed (temporarily); waiting for my buddy to come by and help install permanently and assist in swapping e-brake and armrest covers.

Original automatic shifter plate still installed under the boot and is actually pressed fitted (with some 3m tape) into base..... will change once finalized..... probably during the week.

Here are a couple of pictures......




Boot a little tight @ moment when in park, but hangs nicely when in gear.... May order slightly longer boot if really needs it (this one is 1" longer than stock standard boot (estimated).....

10-18-2010, 07:44 PM
where are you ordering this from?

i know of a place in sauga that you can get decent stuff, but not sure if you are ordering online or not?
im a fan of standard colour (personally). work looks good.

but you should work on doing the whole part as CF...not just covering ;)

10-19-2010, 12:04 AM
where are you ordering this from?

i know of a place in sauga that you can get decent stuff, but not sure if you are ordering online or not?
im a fan of standard colour (personally). work looks good.

but you should work on doing the whole part as CF...not just covering ;)

I'm ordering material from California @ the moment. Have heard about place in Miss/Etobicoke that apparently has everything I need, but haven't checked them out yet. Will before placing next order. Supplier from California has good prices, combines shipping on multiple items (as I usually order) and I don't pay HST because it's a US shipment.

I may consider doing whole parts later on if business continues to grow, then you'll seeing them on eBay.... LOL.... However, molds are specific to the parts being made and right now I've been wrapping a lot of different sets and parts... I'm being given 2 vacuum pumps this week to experiment with vacuum bagging (first step to making parts from scratch) and all the accessories required. It'll allow me to wrap more complex parts easily, but when I wrap by hand I can adjust the cloth if the weave isn't perfect, etc.... something vacuum bagging eliminates (that's why so many commercially produced parts have bad weaves around complex parts.... no way to control cloth once "in the bag" and vacuum applied.....Additionally, since each set consists of 8 pieces, I'd have to be running multiple bagging pumps simultaneously and THAT would likely create a problem with the neighbours who are more interested than upset @ the moment @ my new endeavours.....

So, I'll try and experiment and see how it goes on a couple of pieces and go from there.....

here's a picture of the centre console. Colour will "richen" as I apply more resin. Needs a minimum of 2-3 more before clear coating. Before anyone comments; yes it's very rough and edges aren't trimmed 100%. Rough trim initially and additional/final trim tomorrow. Then light sand, wash and apply another coat of resin tomorrow. Should look sweet when completed.... Also, picked-up a commercial exhaust fan for the paint booth I'm building to provide a dust-free environment in which to apply clear coat.... Now just need to finish enclosure in between sets.... LOL


10-20-2010, 06:46 PM
Hey you still wanna do the seats? pm me with a price

10-20-2010, 10:55 PM

I can see the sign above your garage...

"Nachos23 Custom Carbon Fibre Shop"

Good job....

nope:::: Carbon-effects is the name..... .ca is the link....*th-up*

10-20-2010, 11:12 PM
Hey you still wanna do the seats? pm me with a price

PM'd *th-up*

11-02-2010, 05:00 PM
composites canada ..thats the place(just remembered lol)

11-02-2010, 10:28 PM
Hey thanks.... Ya, familiar with those guys but, they don't post prices on website and run 9-5 hrs, so never bothered calling them... Probably should, but not a conversation I should be having in office.... LOL.....