Here's the process:
- machine custom v-brake bosses out of aluminium that closely match the teardrop cross section of the rear triangle's stays;
- remove paint from frame and roughen surface;
- bond v-brake bosses to frame;
- wrap bosses and frame with a light layer of fibreglass - this is to provide electrical insulation between the carbon fibre and the aluminium frame. Failure to do so can result in galvanic corrosion (ie. you're now riding a battery and not a bike);
- apply epoxy and start laying up the carbon fibre tape, cris-crossing and interweaving for maximum strength;
- apply shrink wrap tape and heat to shrink - this will force the epoxy out from between the carbon fibres and result in a much stronger and lighter part;
Resources links
- Carbon Tow (ribbon) - www.carbonology.com/carbon-tow-ribbon-p-10.html
- Epoxy resins - www.carbonology.com/epoxy-resins-epoxy-resin-systems-c-131_135.html
- Shrink tape - www.carbonology.com/shrink-tape-10-at-100deg-c-1-inch-width-p-111.html