[TAftonomos]

Well, I've been trying to make a carbon/kevlar exhaust shield now for some time. The first few times, I think I was pulling to much vac (~22") and getting large voids in the resin surface of the part.

I tried turning the vac down, and finally got the exhaust guard to turn out without large voids in the resin, however I've got 3 spots now that have tiny tiny bubbles.

Not sure what I'm doing wrong, but any advice would be helpful. Here is my "process"

Wax the part with mold release wax - let dry/buff
wipe on PVA - let dry

cut out pieces of carbon to size
cut out breather and peel ply to size as well

mix up the epoxy. I stir for 4-5 mins, pour into another cup, stir, and then pour back in the first cup and stir some more.

I'll liberally brush on a coat of epoxy to the part first. Then I'll wet out the fabric on the table, and roll it to make sure it's throughly wet. Place the cloth in the mold/part, and brush it around. I will trace the outline of the part with my finger to make sure there are no bubbles/pockets in there.

I do this with the second and third layers as well.

Finally, in the bag it goes, squeezed to 12" last time.

Pulled them out this AM when they were still green to trim. Like I said, no voids, but tiny bubbles make the part ugly.

Sucks seeing seven of these nice looking things sitting here that I cant use, but I'm not going to let this crap beat me!