'73 Suzuki GT250 - Part 19 - Carbon fibre rear fender

Here's a quick overview how I made a plug and one piece fibreglass mold for replicating '85-89 Honda CR250R rear fender out of carbon fibre. I used same method with front fender I posted earlier so I won't go through steps here with same detail. 

I'm pretty pleased with the result. I only used two layers of carbon fibre cloth which ended up with a very light part. I might do another one later with three layers of cloth to achieve a bit stronger and less flexible piece.

Next steps would be to make a lower piece for the rear fender and a seat pan out of carbon fibre. I have not fully figured out yet how to make plugs and molds for those pieces. I've also been planning modifications to my '01 Honda CBR600F4i PC35. Hopefully I can figure those out and share some of them within this year. Happy new year!

Plug made out of pieces of wood and
sheets of polypropylene

Plug waxed and taped

Close up of waxing and taping

Two layers of gelcoat

Fibreglass and polyester resin
applied on top of gelcoat

Excess fibreglass cut off with scissors and
trim lines marked with ballpoint pen

Edges trimmed with an angle grinder

Closer look of imperfections
in the mold caused by wax surface

Look after first round of wet sanding

Masking with vinyl tape

Surface after two coats of gelcoat

Surface after wet sanding up to 600 grid

Mold waxed and ready for hand laminating

Vacuum bagging after hand laminating

Vacuum bag, peel ply, release film and
breather cloth removed after vacuum bagging

Third attempt gave best result (left)

Part after separating it from mold
and before trimming edges of it

Edges vinyl taped and ready for trimming

Edges trimmed and part ready for clear coat