My first CF project: Integrated Saddle & ISP Topper

[WannabeWeenie]

I think this project is far along enough now for me to post on here. This is my first ever CF project for a bicycle. I have created intake runners and tuned pipes for cars and two-stroke motors before but those were not primarily load-bearing CF structures whereas this one is. On top of that, this one supports my ass so visions of CF shards shredding my posterior figured heavily in my choosing to embark on this project (or not).

Many thanks to Clannagh who graciously accepted my request to let me pick his brains. His wisdom has guided me the entire time and has saved me from many potential pitfalls.

This is what prompted me to start this project:


My Litespeed C1R came with an FSA K-Wing ISP Topper that is acknowledged as being the heaviest ISP topper ever. Together with my Selle SMP Lite 209 saddle, it comes out at over half a kilogram.

[WannabeWeenie]

The first step was to make an impression of the inside of my ISP. This was done by using expanding foam. A rabbit wire armature was fabricated to make sure the foam would come out in one piece. The inside of the ISP was lined with peel ply to keep the foam from sticking.

[WannabeWeenie]

From the foam impression, a female mold was made.




And then the ISP Topper was molded.

[WannabeWeenie]

After a whole lot of sanding, the ISP topper and saddle are ready to be joined.

[WannabeWeenie]

Initial attachment of the saddle to the topper with roving. This will get resined in first to fix the position. Additional layers of woven tape will be added to add strength.

[mariovalentim]

you wont be able to move your saddle anymore? o.O

[WannabeWeenie]

No, there will not be any adjustments possible. I have been satisfied with my saddle position for the last three years so I am pretty confident in doing this.

[Jmdesignz2]

Please share your source list ?
Specific Resins, fibers etc?
Links?

[WannabeWeenie]

For the topper:
Fibre Glast 1-1/2" 3K Braided Biaxial Sleeve 2608-A
http://www.fibreglast.com/category/s?keyword=2608-A


ACP Composites EZ-Lam HT
http://www.acp-composites.com/acp-ez.htm


I have the resin left over from tuned pipe fabrication. I would not have used a high-temperature resin otherwise.

The saddle is an eBay Chinese knockoff of a Selle SMP Full Carbon. Use at your own risk and this site does not endorse using copies.

I can't remember where the roving came from, sorry.

[WannabeWeenie]

Fabrication is complete.




The collar is to stop it from sliding too far into the frame. I am going to let that cure overnight before putting any weight on it.

And of course:

[prendrefeu]

The saddle is an eBay Chinese knockoff of a Selle SMP Full Carbon. Use at your own risk and this site does not endorse using copies.

...just wondering if you wrote that or a moderator wrote that for you.

[WannabeWeenie]

...just wondering if you wrote that or a moderator wrote that for you.

I wrote the first half, the moderator wrote the second half and added the red highlight.

I'm grateful they did not lock or delete the thread.