Real Carbon-Fiber - How-To

The carbon fiber popped off the PVC very easily since I waxed the PVC before taping the first layer of weave to it. I rough-cut the carbon fiber with a reciprocating saw, using MDF as a template. After rough cutting, I fine-tuned the cuts with a dual-action sander using MDF as a template once again. With the carbon fiber cut to size, I used Duramix universal adhesive to bond the carbon fiber to the aluminum. Ratchet straps were used at all brace points until the epoxy cured.

The end caps were marked for the mounting braces. I taped two holes in the aluminum for bolting pieces of the old strut tower bar, which then bolts to custom steel plates on the floor of the car. To finish the aluminum, I started by sanding out all the deep scratches, then progressively moved up to 3,000-grit before using a polish compound. Spraying water helps to keep the aluminum cool while sanding. The aluminum was masked off to protect it from being scratched, and automotive clearcoat was sprayed over the carbon fiber.

Once cured, the edges of the clearcoat were sanded smooth. The clearcoat was then buffed and the edges of the aluminum were polished. The MM1040 10-inch woofers fire toward the rear deck of the car. Both the woofers and the box weigh in at less than 50 pounds total. The carbon fiber and polished aluminum match the carbon throughout the car and aluminum rear triangle brace in the trunk.

12. The carbon fiber popped...        read full caption 12. The carbon fiber popped off the PVC very easily since I waxed the PVC before taping the first layer of weave to it.	13. I rough-cut the carbon...        read full caption 13. I rough-cut the carbon fiber with a reciprocating saw, using MDF as a template.	14. After rough cutting, I...        read full caption 14. After rough cutting, I fine-tuned the cuts with a dual-action sander using MDF as a template once again.
15. With the carbon fiber...        read full caption 15. With the carbon fiber cut to size, I used Duramix universal adhesive to bond the carbon fiber to the aluminum. Ratchet straps were used at all brace points until the epoxy cured.	16. The end caps were marked...        read full caption 16. The end caps were marked for the mounting braces. I taped two holes in the aluminum for bolting pieces of the old strut tower bar, which then bolts to custom steel plates on the floor of the car.	17. To finish the aluminum,...        read full caption 17. To finish the aluminum, I started by sanding out all the deep scratches, then progressively moved up to 3,000-grit before using a polish compound. Spraying water helps to keep the aluminum cool while sanding.
18. The aluminum was masked...        read full caption 18. The aluminum was masked off to protect it from being scratched, and automotive clearcoat was sprayed over the carbon fiber.	19. Once cured, the edges...        read full caption 19. Once cured, the edges of the clearcoat were sanded smooth. The clearcoat was then buffed and the edges of the aluminum were polished.	20. The MM1040 10-inch woofers...        read full caption 20. The MM1040 10-inch woofers fire toward the rear deck of the car. Both the woofers and the box weigh in at less than 50 pounds total.
21. The carbon fiber and polished...        read full caption 21. The carbon fiber and polished aluminum match the carbon throughout the car and aluminum rear triangle brace in the trunk.