With
the
mirror cover removed start by drilling several small holes, 3/32 or
smaller, in
the mirror cover. Position several holes around any edges or corners.
These holes allow resin to flow through as it cures which
helps prevent delamination.
Using
120
grit sandpaper, sand down any ridges that the holes may have created.
It is not necessary to remove all of the paint, but it does need to be
roughed
up. Try not to sand through the primer, as the resin will more
consistently
bond to paint or primer.
After
sanding thoroughly, wipe down the cap with paint thinner to remove dust
and any oils. Now lay the cap down on your roll of carbon fiber and cut
out a piece that is at least 30mm larger on all sides than the cap.
Using 3M Formula 77 or 90 spray adhesive, lightly coat one side of the
graphite piece you
just cut. Apply the cut piece to the mirror taking your time to
preserve the pattern and prevent creases.
With
the
graphite applied to the mirror you are ready to coat with your
preferred
resin system. Normally an epoxy resin would be used for
carbon fiber, but in the case of a simple wrap, polyester resin is
adequate if you will be finishing the job with a UV resistant clear
coat.
With the piece totally wet out with resin, place it in a vacuum bag as
shown in the earlier guide here: Intro
to vacuum bagging.
After
the
mirror has had time to cure you should carefully remove it from the
bag.
At this stage small resin creases and stray fibers are normal.
Using a razor you can easily trim the mirror cover to its exact final
shape. Using progressively finer sandpaper remove any excess resin
using care not to cut into the carbon fiber. Should you have
any air pockets or low spots you will need to brush on another thin
coat of resin much like you would paint. Allow the resin to cure and
then carefully repeat the sanding steps.
At
this
point the graphite will have a flat appearance to it. If you are going
for the industrial prepreg look be sure to use epoxy resin due to UV
exposure. If you want this look, all that is left is to
polish the graphite. Finishing with 2000 grit sand paper will give you
a
uniform look.
If
you
want the more typical deep rich shine, you will need to add a layer of
clear coat. Clear Imron 5005 works extremely well due to its UV
resistance and
hardness. If you are not equipped to spray 2 part paints, a local body
shop can help you out for only a few dollars.
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