Braden1550

I've made a lot of things out of carbon over the past couple of years, most notably, a full monocoque carbon/kevlar human powered vehicle for 24 hour hpv racing in australia, as well as 6 hour events. I gave my mountain biking friend a seat to use, but it was too long for his needs and so he gave it back. Whilst I found the seat too cushy for my own liking, I have decided to turn it into a mold, and using 4130 rails, I will make myself a carbon seat using Unidirectional carbon (SEXY!!).

This will be my little project thread log, and so you can all see how I went about it. BTW, I should add, this won't save much weight at all from my Arione, and yes, there is always an element of risk. Especially where your bum is concerned. I'm attempting to minimise this by using metal rails...DIY Carbon rails, maybe not. I may do them next time, however they will be carbon wrapped rather then hollow carbon. I don't have vac bagging stuff in my shed, nor a couple grand for the tooling to do hollow rails. This project parallels the ergonomic carbon lounge chair I recently finished.

Why?
Why not.

chado445510

That sounds like a great project. I'm very interested. I'd also be interested in that chair you built. Pics?

AngryScientist 

cool !

laying up cf is actually not that difficult, and it sounds like you have a good knowledge base to do it. it also sounds like you have thought it out well, a saddle should be a relatively low risk piece to make. definitely keep is posted as to the progress!

midgetmaestro 

Subscribed

mymilkexpired

Sounds really cool. Going to watch this.

Post up some pics/links to your other projects!

merlinextraligh

It was a million to one shot, doc.

sbxx1985 

I was skeptical until the ergo carbon lounge chair. Pics, please.

midgetmaestro 

Bump. Has there been any progress?

Braden1550

Indeed. Interstate trip in which my camera was destroyed. Looking to borrow another so I can back it up

The Layup on the ergo chair is well and truly finished But the Aluminium Armrests/legs have yet to be bolted on. This is the "Prototype" Ergo chair, so the future ones will hopefully have carbon armrests and legs. I'm a cheap bastard. I can get carbon cheap/free, and resin, and my own time is free, and cheaper then nice furniture .
I made and released a carbon shell from the bike seat mold, and experimented with carbon wrapping for the 4130 rails (in future will try carbon wrapped aluminium rails/ask baum to make me ti rails). Hot tip for DIY'ers;whenever carbon wrapping something (most likely aluminium) it's imperitive you use a layer of fiberglass first. Thisis the insulate the alloy from the carbon and cause cathodic corrosion.

I'm dissatisfied with the carbon seat shell i initially released-The layup I intended to use came out too flexible, and the additions made it too stiff. I'm trying to recreate the intended flex of the Selle Italia Flite Evo 3 I had albeit, with a surface texture that offers some friggin grip!.

Unfortunately, in the middle of mid-year exams for Final year high school. Not fun. Haven't ridden more then 10km's in the past 4 weeks. Nor been online to visit this thread

Being a archetypal DIY kid, I've got my eyes on a homemade ISP frame it's a pipe dream at this stage, but it's been done before. And I have no delusions-it won't be as good as my TCR at all.

EDIT:
I should add that I made the seat shell originally out of a standard weave-Uni simply wouldn't conform if I used 1 cut (Another tip-make your stuff with as few pieces as possible. Stronger, cleaner, more efficient, neater, more professional). The next will be either several pieces of uni, and a pure show-piece (could be ridden but you wouldn't) or probably (most likely) made in 2-5 stages, of around 2-3 cuts of cloth.

NathanC

midgetmaestro 

Sweet - keep us updated when you get time away from school.

oilman_15106

Anyone have a picture of the stone saddle that was on Sheldon's web site? Once your done with your present project you can start carving another one.

nathan84318

this one