A DIY Carbon Fiber Mast

Post any and all methods for doing things here, if you think you have a good method, that you don't see most builders using
Alext
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Re: A DIY Carbon Fiber Mast

Post by Alext »

https://dragonplate.com/carbon-fiber-vs-aluminum

http://www.dexcraft.com/articles/carbon ... materials/

I’m not sure how much I would bet on this. I would still want to test it in the specific context but.
Studies show that 2 directional carbon fiber with common modulus, has 30% more stiffness and
60% more ultimate strength, when compared to aluminum with the same wall thickness.

There are many grades of carbon fiber with different modulus.
The stiffness increases as the modulus, however ultimate strength decreases.

From what I can see the disadvantage of CF is that although it will flex and bend, it always
Wants to return to its original shape. When it reaches its limit it breaks..
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fallguy1000
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Re: A DIY Carbon Fiber Mast

Post by fallguy1000 »

Curious why not try infusion?
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Alext
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Re: A DIY Carbon Fiber Mast

Post by Alext »

I hadn’t thought of that. I’ll be looking into it.
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fallguy1000
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Re: A DIY Carbon Fiber Mast

Post by fallguy1000 »

Alext wrote: Wed Nov 09, 2022 6:48 pm I hadn’t thought of that. I’ll be looking into it.
I think you wrap it with 3M spray glue and then pull the resin.
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Alext
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Re: A DIY Carbon Fiber Mast

Post by Alext »

So here I am, a little over 36 hours later. The temp is lower. It’s solid with still
a little flex in it. I hoped it would be perfectly straight, but not.

Image

I will add some more layers with the sail way. Today I glued the PVC that will
become the sail way. I think I will add 3 more layers to this.

Image
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narfi
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Re: A DIY Carbon Fiber Mast

Post by narfi »

I used pex tubing for my sail track, and while it works, I was not as happy with it as I had hoped. I did not put enough time and thought into the jig for cutting the slot and it was not uniform, so there are tight and loose areas. I sanded the tight areas to make them work, but loose areas can be an issue. I ended up not being able to slide the bolt rope of the sail through it and used plastic slugs which worked much better.
I did the same on the boom, but I cut the slot too loose for it and when using on my ice boat (which puts more force on the sail than the trimaran) it pulls out. So I ended up needing to lash the sail down to the boom to keep it from slipping out.

Just some thoughts :) your pvc might be harder than the pex I used and you are probably smarter in cutting your groove after...

I love seeing projects like this that are inventing on your own "outside of the box"

Alext
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Re: A DIY Carbon Fiber Mast

Post by Alext »

Thanks for the comment. The Idea is to have the PVC provide the form. Layers of FC fabric will wrap around the mast and now include the sail way track. The strength will come from the FC and epoxy. When the FC cures I will draw a line with chalk and grind the slot with my angle grinder. Very carefully of course. BTW all of the ideas I will be using for the accessories are from, or inspired by, the tutorials on this site.
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fallguy1000
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Re: A DIY Carbon Fiber Mast

Post by fallguy1000 »

Alext wrote: Thu Nov 10, 2022 5:21 am So here I am, a little over 36 hours later. The temp is lower. It’s solid with still
a little flex in it. I hoped it would be perfectly straight, but not.

Image

I will add some more layers with the sail way. Today I glued the PVC that will
become the sail way. I think I will add 3 more layers to this.

Image
Consider getting it straighter and leaving it cure longer that way. Takes epoxy a good week for full cure and if you postcure; it can change shape still.
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Alext
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Re: A DIY Carbon Fiber Mast

Post by Alext »

Jaysen wrote: Tue Nov 08, 2022 7:48 am I’m not sure if your “thickness equivalency” is correct. I checked a round mast here on a freedom 40 and it was much thicker
than an aluminum equivalent.
I think I may have chosen the wrong modulus of CF. This article shows a comparison between CF and aluminum by
weight and by wall thickness.

http://www.dexcraft.com/articles/carbon ... materials/

The common (standard) modulus CF has 160% the ultimate strength of the same thickness of aluminum. As the modulus increases the stiffness increases; ultimate strength decreases.
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Alext
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Re: A DIY Carbon Fiber Mast

Post by Alext »

Another test by Dragon Plate

https://dragonplate.com/carbon-fiber-10 ... gh-modulus

Shows strength and stiffness numbers of different grades of carbon fiber. Strengths are nearly equal,
between standard, intermediate and high modulus. I’m more confused now than before.
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