I'm looking for a simple way (that doesn't require high pressure chambers or state of the art tools) to permanently bind a set of carbon fibre pieces in order to make the frame of a chassis that could be used in a go kart or dune buggy or even a boat? (watercraft is just a bonus, it just needs to support the weight and impacts of a 300kg vehicle, including the driver).
The raw pieces of carbon fibre are as follows:
2 x 10mm square/round tubes (up to 1500mm length) For the outer frame's longitudinal beams (shown in blue)
6 x 10mm-by-5mm strips (up to 600mm length) For the outer frame's lateral beams and cross-diagonal support beams (shown in green)
2 x 10mm rods (up to 800mm length) For a longitudinal reinforcement, also to be sticking out as an axle mounting point (shown in black)
1 6mm thick (very large) sheet of carbon fibre cut to shape and cover the chassis, walls and crevices (not shown)
The methods I'm aware/capable of are:
- Drilling/tapping screw holes
- Using epoxies and other chemical adhesives
- using carbon fibre vinyl as a tightly wrapped joint
- Using ropes/cables where a long piece protrudes from the body
That last method I believe is useless in a carbon fibre build, however I have plenty of access to steel materials and the tools to cut/bend/drill them into virtually anything, would this serve any use for my build?
I'm thinking about drilling holes to make mounting points which I can then glue together and seal off with a washer or bung or a locking stopper.
My real questions are (TLDR):
How does drilling holes into carbon fibre affect its structural integrity?
Which bonding agents are ideal for carbon fibre in a structure that needs to withstand impact from many directions (especially up-and-down)?
Is it beneficial to use both steel and carbon fibre together in the same structural component?
Are there any composite material alternatives to Carbon Fibre that are just as, or possibly more applicable to this type of structure? I'm looking for something with a light weight, high tensile stress, resistance to abrasion and of course, a decent price.
Thank you. Please forgive if this question is elementary, I've not been researching composites for long but can't wait to build something.