FLASH-POINT BLOG ARCHIVE: May 2005

Used the last of the prototype material to build some new rims. Changed the laminate to drop some weight while leaving in enough material to be strong. Only got two out, one of them has a molding problem. Will give them to Erik to ride, telling him to use caution.

The Flash-Point material was cut up for use in cranks! We need to find out when we can get some more. (I wonder how those cranks will turn out)

Gave Joe another set of FP-40s.

Impact tested some wheels on the drop-tester. They performed well.

Molded new wheels using a more reasonable laminate structure (still probably over-built). We'll see if this generation builds well.

Found out that there was a problem with the drilling machine, giving off-center holes, which caused our nipples to hit the side walls, causing the cracks between spokes.

After riding 60 some miles through the hills in the heat I was tired and left the front wheel behind my car while loading the bike on the roof rack. As I am backing up, the car runs over it and I hear the sound of splintering carbon.

Game over. The rim is torched, several spokes are bent and my quick release is now s shaped. I think the hub is ok, but I am not going to salvage it. I put about 1000 miles on the hubs and after the initial loosening was addressed, had no problems at all.

Molded rims with more sidewall strength. We now have rims that should be darn near bomb-proof. Boy are they heavy.

We construct the rims from assembled pre-processed parts in a jig. There is considerable skill involved in getting the carbon lamination made correctly. Our operators learn to produce near identical items which are molded as soon as possible.
Molding is another fine art. The operator has to ensure the open hot mold is free of resin flash and debris, judge the correct quantity of mold release to apply to ensure the molded part will not adhere to the metal and place the lamination exactly in the open mold cavity - otherwise there is risk of pinching the material.The molding presses are computer controlled. Temperatures and bladder inflation rates are pre-programmed to obtain the best surface finish.
Molds temperatures are critical as variances in either direction can have highly undesireable effects. This process technology is so unique that it is currently "patent pending". 
After molding the rims are placed on the lathe and the brake surfaces cleaned up with a special diamond coated cutting tool. Another QC inspection, then these rims are sent for drilling and built into wheels.
That part of the story we will leave for another time.

Joe broke his wheels. A number of the nipples pushed into the side walls, mainly on the rear wheel.

Built up more rims, same result.

We have a couple that look pretty good, so we'll give them to Joe to ride.