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Last Post 25 Feb 2011 10:41 AM by  The Machinist
History of the Terrashark and EPX carbon frame
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magpies14
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12 Aug 2009 6:50 PM

    Hi Robert,

    Just wondering if you still have any pictures or information of how our EPX terrashark frame was formed ...

    This was taken from MBAction review :


    THE EPX FRAME IS CUT
    Carbon material (it has a grain) is cut into shapes (similar to how a tailor cuts out the pattern for a suit). Each piece is cut with a specific job in mind.
    Some will be cut with the carbon fiber grain running one way, others with the carbon grain opposing.
    This lay-up allows the frame to be tuned so it is strong and stiff in one area (like the bottom bracket), but with compliance in another (the seat mast).


    THE FRAME IS MOLDED

    The carbon fiber (already impregnated with resin) is ready to be cured.
    The cut pieces are laid up into the mold with a specially formed nylon bladder inside the wrap.
    At this stage the frame looks like a deflated balloon in the shape of a bike frame.
    Once the lay-up procedure is finished, the steel molds are closed and the whole package is gradually brought up
    to curing temperature with the pressure inside the bladder increasing to assist the forming of the carbon against the mold.
    The final pressure of about 110 psi and temperature of 180 degrees Celsius are achieved about 45 to 60 minutes into the process.
    At this point, the pre-impregnated resin has saturated the carbon fibers and the whole matrix is bonded together.
    Then the mold is allowed to cool to about 80 degrees Celsius before the new frame is ready to be released.

    Anyone can enlighten me about what and how to care for our Terrashark....what we should look out for and note...

    thanks once more...

    Dark Knight EPX Terrashark 18"
    robert
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    13 Aug 2009 12:37 AM
    Hi Magpies,

    I'm meeting up with one of the designers, Andrew, and I'll ask him for some further details. I'm also organising to get photos of the production and anything else interesting off him for the site. I should also ask my brother-in-law (owns the Syndey design firm that originally designed the bikes) and see if he has some material handy. I've just had too much on for the last few weeks to get around to it

    As far as I'm aware there isn't actually anything in particular that you need to, or even can do, for the frames. So long as the resin isn't cracked, and you dont' use any nasty solvents on them, the frames are basically zero-maintenance. I put some thick, urethane tape down the sides of my Terrashark frame when I got it and that has kept the finish in good order. The only thing that has been bad is that rubber stop-piece on a Speedster frame I got off Evan. I'm still in need of a replacement for that.
    Rob
    magpies14
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    Posts:56


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    13 Aug 2009 1:53 PM
    That's great Rob....looking forward to see those info soon...

    Reason why i asked about the 'care' of the carbon question is that lately i accidentally scratch the frame (between rear shock and the frame) for about 3 cm length...it's not deep but a scratch, but as you mentioned as long the resin isn't cracked then it's fine...

    thanks again Rob for taking care of this website....
    Dark Knight EPX Terrashark 18"
    magpies14
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    Posts:56


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    13 Aug 2009 3:57 PM

    Guys, just somehow manage to bump into this site

    http://www.powerhousemuseum.com/unp...design.php

    It's Nielsen Design from Sydney as Rob mentioned earlier.....

    Rob, look forward to see more information ....those prototype design looks awesome...

    Bump into these EPX family bikes :

    EPX 303 : http://www.bikepedia.com/quickbike/...;Type=bike

    EPX Ultegra : http://www.bikepedia.com/quickbike/...;Type=bike

    EPX Speedster : http://www.bikepedia.com/quickbike/...;Type=bike

    EPX Hammerhead Comp : http://www.bikepedia.com/quickbike/...;Type=bike

    EPX Hammerhead Pro : http://www.bikepedia.com/quickbike/BikeSpecs.aspx?Year=2003&Brand=EPX&Model=Hammerhead+Pro&Type=bike

    EPX Mako : http://www.bikepedia.com/quickbike/BikeSpecs.aspx?Year=2003&Brand=EPX&Model=Mako&Type=bike

    EPX Nullarbor : http://www.bikepedia.com/quickbike/BikeSpecs.aspx?Year=2003&Brand=EPX&Model=Nullarbor+-+Dura-Ace&Type=bike

    Dark Knight EPX Terrashark 18"
    magpies14
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    21 Sep 2009 5:56 PM
    hi there Rob, by any chance that you have the below specification of the Terrashark ?

    top tube length -
    head tube length -
    head tube angle -
    Seat tube length -
    Seat tube angle -
    BB height-
    Wheelbase -
    Chainstay -
    Standover Height Range -

    thanks...
    Dark Knight EPX Terrashark 18"
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