Sib, my shopping list is in the first post. I don't think it's an exaggeration to say I have enough material leftover to do this eight more times. There is plenty of material to test and test.
I spent under $35 on material. If I were doing this again, and knew what I know now, I wouldn't bother having two different weaves. This would have come out just fine using plain-weave, or 2x2 twill. I'd pick the plain weave.
As for time.... as you mentioned, prep is where I spent the most time. Start to finish....the day it broke was Friday May 5. Eleven days later, I was riding again.
The 11 days included Saturday crying
.....and agonizing over what to do next..... Sunday on YouTube and blogs, Monday ordering supplies..... a few days waiting for them to arrive. All coupled with a busy job and life.
The steps (if I did it again) with time estimates (ignoring my test work)
- Sanding - an hour
- first carbon wrap - an hour
- 24 hour wait (first 10 hours heat lamp)
- Coat of epoxy- 30 minutes. allow to get tacky, wait an hour
- Final covering of carbon fabric for looks and protection - an hour
- 12 hour wait.
======DAY THREE OR TWO (either would work, I'd go with day 3)========
- Light sand high spots
- Final coat of epoxy as a smooth clear coat. Maybe two coats, using the same batch of resin, spaced out from beginning of mix, to 40 minutes later (nearing the end of the mix's pot-life)
- Final heat and dry day.
I feel confident I could do a job like this again in a few hours over the course of 3 days.
I'm also confident I spent more time with the pictures and writing up the thread, than the time spent actually doing the repair......if it saves just one other frame, it's all worth it.
Since we're on Weight Weenies.... at least we all already own really nice scales, to help us do a good job with resin mixing. I wouldn't recommend doing this without a scale. Unless you mix big batches of resin, and have good graduated cups. My biggest batch of resin was only 30 grams (20 resin/10 hardener). Most of that got rolled out in the plastic, or squeezed out in wrapping.
I did all the work with a single sheet of 100 grit dry paper. If I wanted a cleaner line look, I'd go over it to get all ripples out with 320, then go up in grades, 500,800,1500,2000 and then a polish (Meguiers Scratch X) for glossy, or a final run with Scotchbrite pad for matte finish.
This is what five minutes with Scratch-X can do for you (another project of mine).....