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In this tutorial we demonstrate a technique for skinning/wrapping a car center console using ForgeTEX® Premium Bold® forged carbon fiber dry fabric. The method shown here does not require vacuum bagging.

0:15 Preparing the Part for Wrapping
1:19 Applying ForgeTEX® Forged Carbon Fiber and Resin
5:18 Creating the Smooth Gloss Finish

Details:
1. Existing cover, foam and adhesive are removed and plastic is keyed with rough sandpaper for a good mechanical bond. New foam is added to fill the top space. Foam is sealed with epoxy resin to created a surface suitable for skinning. Back of console is covered to protect attachment clips from unwanted bonding.
2. ForgeTEX® forged carbon fiber dry fabric has been cut to size using the old cover as a template, and the clear film backing has been removed. Epoxy resin is spread onto a sheet of silicone coated nylon peel ply before placing the carbon fiber face down onto the peel ply. Additional resin is spread onto the back of the fabric to saturate the forged carbon fiber without damaging the Premium Bold™ pattern. A roller removes trapped air and helps to ensure complete wet-out. The console is coated with resin and then placed onto the carbon fiber/peel ply layup. It is then wrapped around the part using the peel ply to manipulate the fragile carbon fiber into position. Relief cuts are added to the nylon peel ply as needed to conform to the console shape. Long strips of plastic peel ply are used to tightly wrap the part and compress the forged carbon fiber against the console base. Tape is used to further secure the strips in place while the part fully cures. Alternately, the part could be vacuum bagged.
3. All peel ply is removed from the cured part. Edges are trimmed and the entire part is sanded with 220 grit paper to remove high spots, using the texture from the nylon peel ply as a guide to avoid sanding through the forged carbon fiber skin. To build up the cosmetic gloss finish, the part is coated with epoxy, cured and sanded. This process is repeated as needed until all low areas are filled. The part can then be further polished to a gloss finish or an automotive clear coat can be added for a full gloss finish plus UV protection.

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