I layed up the first prototype helmet from the pooleman mould on Thursday with a carbon, kevlar, glass, glass, kevlar construction with epoxy resins. 
The production didn't go entirely smoothly as the gel coat was still tacky as I was doing the carbon which made it difficult to properly lay out and compress the weave into the correct shape for the helmet. Likewise my kevlar at the moment is a standard weave and not a twill weave so won't fold into the helmet shape in one piece so this will look scrappy and won't help with the strength of the finished piece.
The production didn't go entirely smoothly as the gel coat was still tacky as I was doing the carbon which made it difficult to properly lay out and compress the weave into the correct shape for the helmet. Likewise my kevlar at the moment is a standard weave and not a twill weave so won't fold into the helmet shape in one piece so this will look scrappy and won't help with the strength of the finished piece.To fix this I will wait more time after the gel coat before applying the carbon next time so that it is not tacky and can be layed in properly before a single piece of pre-whetted biaxial glass is layed ontop which will whet out the carbon and hold it down. I'm going to source a different supplier for kevlar whocan do it in a twill weave which will also fold into shapre without being cut. Hopefully prototype two will start late next week.
Laters.
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