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LAST UPDATED 27th NOVEMBER 2007

See How

This page contains just a few "How we produce" items. We will shortly be adding to this so please check back regularly.

Index:

3-Maching the new ATP Billet Cylinder- Scroll down

2-See what an ATP Cylinder Head starts life as- Scroll Down

1- Carbon Pre-Preg Hood, Baffle and Front Cover -Scroll Down

-Back Flip Mod to rear of ski- Try This it's free > more info

 

 

  

 

3 3- Introduction

Just a few Pictures showing the process of machining from a "Billet" of  Aluminium a two stroke Jet Ski Cylinder made in house by ATP.

This can be seen on ski here, this is not a "Dummy" ski but a fully working, shoulder dislocating, Pro machine.
 

 

 

 

 

 

 

 

 

 

 

 

 

2 2-Introduction

Before and after pictures of the ATP "Snake" Billet (Girdled) Cylinder Head, made in house by ATP.
From this   To this
 

 

1 1- Introduction

Pre-preg is an abbreviation for "Pre impregnated" (with epoxy resin). Carbon Fibre Pre-Preg has the correct amount of resin to Carbon ratio. This gives superior strength and cuts down on weight.

Wet lay up, using any dry composite and resin can result in either too little or too much resin being used and both can cause the laminate to be weaker. Even a laminator with years of experience can struggle to get the correct composite to resin ratio.

The following hopefully gives you a good idea of what exactly goes into making one of our Carbon Fibre Hood kits made in house by ATP.

  
  Carbon Fibre Pre-Preg defrosted and ready to go

(Photo makes Carbon look yellow but it's black)

  Pre-preg is measured and marked out. Each layer needs to be laid into the mould at varying angles to make sure strength applies to all areas of the product.  
 
  1st Layer is applied. Due to the nature of pre-preg, templates must be accurate as pre-preg will not conform to complex shapes and angles.

The first layer is now complete.

 
   

 
This must now be "de-bulked". This involves covering the carbon in a release film and breather material again both of these must be cut and tailored to fit as they will not conform to shape even under such vacuum. Special high temperature sealant tape is applied to the flange which the vacuum bag is then attached.

Picture shows vacuum bag under pressure.

 Once de-bulked release film, breather and vacuum bag are removed and subsequent layers are then applied. A core material is needed. The "core" material we use  helps to strengthen, stiffen and absorb impact, Carbon Fibre alone has poor impact resistance. This core material needs to be covered in an adhesive film (sheet form of Epoxy Resin) for several reasons 1- To hold core material in place during lamination 2- Without it core will draw in resin from the pre-preg, this would then leave the carbon resin dry 3-This makes the core become part of the lamination.  

In the areas where core material isn't applied e.g. near to the trim line, handholds, bonding line for the baffle, extra layers of Carbon are applied.
 

 
 
After the core material has been laid into the mould this will also need to be "De-Bulked" in the same way as described before (using new release film and same breather & bag  used for 1st de-bulk). If we didn't de-bulk now the core material would cause all subsequent layers to have bridges and voids as it wouldn't be completely formed to the mould.

Once de-bulked the final layers of pre-preg are applied.

 

  

 

 

 

  Once all layers have been applied, it's now time to bag for the final time. New release film, breather, sealant tape and vacuum bag are cut, tailored and then applied. Thru bag connecter is strategically placed within the bag before sealing. Vacuum is then applied making sure there are no voids or bridges.

 Once under pressure the mould is placed in our digitally temperature & time controlled oven. The cure time/rate depends on the type of Pre-preg used but is typically around 8 hours at 80 degrees C. The oven has to take the product up to temperature gradually which can take several hours. The oven will then hold the temperature for the set period and then slowly start bring the temperature down until it reaches the current room temperature. This is just as important as the slow increase in temperature.

  

 
  Now comes the best and worst bit- De-moulding.

All vacuum bag, release film and breather must be removed. The breather material now has some cured resin in it so it's important not to pull/rip it off. We use special wedges to slide under the cured Carbon which is now very hard and razor sharp.  Once a few wedges are under the carbon on the flange a huge whoosh is heard and the product pops up (99% of the time). Now is the time when you get to see that your whole weeks work looks stunning.

  
   

 

 

 Picture shows Hood straight out of mould  different view
 

Now we need to spend the next few days trimming and bonding  with a structural adhesive.

It really is worth the work when you produce this............

  

The baffle and front cover are made in same way including the core material, a set of hand hold buckets are also made in the same way but without the core material.
 

Picture showing baffle core material

Picture showing Baffle with release film

  
   
 
 

Picture showing breather material.

Picture showing Baffle bagged down.

  
   

Baffle/liner straight out of mould
   
Bagging front cover and handholds  

 
 

We hope you have found this informative and interesting.