Forged Carbon Fiber ... On a Sonex?!
Can Forged Carbon Fiber replace traditional composite methods on a homebuilt airplane? Welcome back to the Sonex project. Today we’re stepping away from the rivet gun and diving into the world of advanced composites. Forged carbon fiber offers a unique aesthetic and impressive structural properties. I'm documenting the entire process of creating a wing-end light stand-off from scratch. We’ll cover: Material Prep: Ratio of chopped fiber to resin. The Mold: Designing for compression. The Cure: Managing heat and pressure. The Reason: Weight savings vs. structural integrity. Whether you're building a Sonex, a Vans RV, or just curious about DIY carbon fiber, this deep dive is for you. Tools & Materials used in this video: Resin: https://www.amazon.com/dp/B01LWT156B Carbon Fiber: https://www.amazon.com/dp/B0C48TR31F Wax: https://www.amazon.com/dp/B0BQCZ8C3K PVA: https://www.amazon.com/dp/B0819Z3XVJ Downloadable STL files on my GitHub repository: https://tinyurl.com/2aa7wcka Molds designed in Solid Edge (free for EAA members)
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