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Brightonuk
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Poor Mans CF

Decided to spruce up the interior from a previous attempt where i had used 1/8" ABS sheet, looking back this was to thick and heavy not to mention very difficult to work with when it came to trying to heat and form.

I addition my finished concept (of one piece and rolling over the door sills was not the prettiest result)

 

So this time I went for a .040 ABS.

The sheets are extremely lite and pliable the carbon effect is not really the one I expected and there are finishes that are a closer match to the  Cycle Wings Dash etc. I just picked the wrong one

The cost to return did not make sense so I decided to use it anyway 

 Passenger side cut and ready to fit.

I am using 3m VHB molding tape (for easy removal the next time I need to spruce it up)

https://www.amazon.com/Double-Mounting-Waterproof-Length-Office/dp/B0829XM2JH/ref=sr_1_7?crid=2NTNU1VYZVH9Z&dchild=1&keywords=3m+moulding+tape&qid=1588458397&sprefix=3m+moulding+tape%2Caps%2C159&sr=8-7

The tape is extremely secure as long as you prep the surfaces I use this stuff once stuck it will not release without a fight.

https://www.amazon.com/gp/product/B07S2GF8GW/ref=ppx_yo_dt_b_asin_title_o04_s00?ie=UTF8&psc=1

To address the badly chipped bow caused by the seat belt 

I molded a strip around the bow from the panel offcuts 

Heated and molded it now fits snug against the body. 

Figure Caterham price just for the bow moldings would cost me over 200 bucks + shipping this worked out great and cost around $0.

If had picked the correct ABS CF finish I do not think you could tell the difference.    

D Jones
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 Very good, was the abs plastic from Amazon as well?

Isnt it amazing the jobs we can find during lockdown

DJ.
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That looks good to me Smile

Brightonuk
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No DecorativePlastics.com here in the US

72 bucks about 55 quid for a 48X 96" sheet Fleabay usually has sellers. 

Life Can Be Crule

garybee
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Like it. As a result I've just ordered some to make a couple of rear wing protectors. I was going to buy or make some in carbon but that'll be far quicker and probably better for impact resistance.
Golf Juliet Tango
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Clever approach. Well done.

Stephen

Democratic dissent is not disloyalty, it is a positive civic duty

Ivaan
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Great idea. I've been looking for ways to spruce up my Millwood rear wing protectors. They're pretty battered, to the extent that in areas, the surface has gone and the weave is exposed.

Will the ABS stretch around compound curves?

Garybee - which supplier have you used?

Cheers,

Clive.

BECs Rule !
garybee
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This is the listing I purchased from on ebay:-

https://www.ebay.co.uk/itm/2-mm-Carbon-Fibre-EFFECT-ABS-sheet-600-mm-x-400-mm-Car-trims-Dashboards-models/361721851782?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

I went with 2mm but I'm only needing to curve it in a single plane.  The bow protectors in brighton's post are a compound curve so it appears that it's possible with 1mm ABS.  I'mm heat up an offcut of the 2mm sheet when I get it and see how much it will mould if you like.

David Brown
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Brightonuk how did you cut it?

Brightonuk
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Stanley knife easy to cut 

The curvature was easy with the 0.40 I just attached each end with some clamps to hold it in place then proceeded to heat the ABS in small sections starting above the lower clamp, just until the ABS starts to soften (it will start to deform) then using a micro fiber cloth (as it will burn you) just fold (squeeze) the ABS around the bow then move up to the next section and do the same.

It will tend to crease as it follows the curvature of the body but just go back and reheat and rub the crease area back and forth while squeezing the ABS against the bow with the cloth. 

Get to the top and remove the lower clamp to finish the base re-clamp at the bottom finish the top.

The width is up to you but too wide and it creases too much  

Here is a 60mm wide against the 45mm 

 

 

 

 

Life Can Be Crule