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How to Work with Carbon Fiber

A good way to join overlapping rods:

Tack the rods in place with a drop of medium CA. -- A SMALL DROP. When this is dry, check that the pieces are properly aligned. The joint will be fragile at this point so work carefully. If you're not happy, break the bond, reposition, and re-tack. If you're happy with the alignment, take any old regular cotton thread (not plastic) and wrap the joint several times all the way around. Soak the joint with thin CA. Wait for it to dry, and then, just for fun try to break it. You'll be surprised how difficult it will be to do.

What happens is that the thread holds everything together, and the CA makes sure that the threads cannot shift, stretch or separate. This is what gives these joints tremendous flexibility and impact resistance. If you only use a couple of turns of thread you will allow the joint to flex in case of a crash or big hit.

You can use the thread/CA method to attach rods to wood or metal pieces. Making joints like this for where the ends of 2 rods have to be joined in an angle like a V is a little more difficult. David's fittings will come in great for V's, T's and L joints. Another advantage of fittings is that they can help you form more consistent and well-aligned pieces. I've ordered some and am eagerly awaiting them too. The other advantage of the fittings for corners is that the ends can get splintery, and CF splinters are nasty.

Look here at the arched roll-bar. I was able to arch the rods, and tack and hold them in position with small drops of CA. I bound them afterward as described above. The small drops of white visible in the picture are the pieces of thread wrapped around each joint. The arches are strong enough that I can bounce the whole thing upside down against a table and it just bounces right back.



To cut rods up to .100" or so, you should use a cable cutter like the one shown below. The V-shaped jaws which will preserve the ends of the rod being cut. A regular pair of pliers will smoosh and splinter the ends. These are made for cutting braided bicycle cables and better bike shops stock them. They cost around $30 but are well worth it.


The V-shaped jaws won't smoosh carbon rods flat, but will instead gather it together as it's being cut to keep the ends neat.


The entire cutter with a quarter for size comparison.