New Project Update 11th February 2004

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Update 9th January 2004

Update 11th February 2004

If you wish to view previous work then links to updates are above. Work before this date was organised in sections (chassis, engine, bodywork etc.) you can see this work by going to "New Project Title Page" above.

All the wings are now made in a carbon, glass composite. They turned out very well and each one weighs about 1750g, but is stiff enough to do its job. Robin has sprayed the front wings, boot and front panel. He will start on the rear wings this weekend.

The fibreglass doors have taken a lot of work to get into a respectable condition. There were lots of voids behind the gel coat and dry areas of glass. One day I will make some carbon doors.

I have wrapped the exhaust in insulation (for heat and sound). The expansion chamber is refitted and is now quiet with the added insulation.

The car is booked for a rolling road tune up to map the engine management system on the 1st March.

Next jobs are to fit the hood frame and the sprayed body panels. Its getting close to being on the road!!

There are 26 pictures on this page, posted 9th January 2004

Cutting Carbon Fibre

Cutting the carbon fibre was quite difficult due to lack of room. Cutting on
the cardboard enabled me to move the whole lot around to allow me
to easily cut in all directions. The carbon is a 2x2 twill and is quite unstable.
If I had tried to move just the carbon fabris by pulling on it it would have
stretched and distorted.

 

Laying up the flange on the front wing.

I was hoping to lay up the wing in one go but due to overhangs I had
to lay it up in stages. Here I am doing the wing lip. I have already done the
mounting flange. I butted CSM into all the corners to ensure no voids.

 

Brackets to hold the wing.

This is the rear of the front wing. These are mounting brackets bonded and then
covered with a layer of carbon.

 

Fitting The Front Wing.

Here I am offering up the front wing.

 

The Front Wing In Position.

The front wing in its position. Notice the small lip by my hand.


The Front Wheel In The Arch At Full Bump.

This is the front wheel on full bump. It just clears the wing with lock on.
I hope it will be unlikely that I have full lock and full bump at the same time.
Notice the bottom of the door with the poor quality finish.

 

Front Wheel Mounting Brackets and Dirt Sheild.

This is looking backwards at the door. The two wing mounting
brackets are visible (this was before they were bonded to the wing)
and the aluminium dirt shield.

 

Dirt Sheild At The Front.

At the front of the front wing I added another removable panel to stop
dirt going onto the headlight.

 

Dirt Sheild With Wing In Position.

This is the dirt shield. with the wing in position. I will put
rubber seal onto the edge of the aluminium.

 

Rear Wing Lay Up.

As with the front wing I had to lay up the rear wing in stages.
This is the first stage around the wing lip.


Rear Wing Before Releasing From The Mould.

This is the rear wing before I ground off the surplus around the edges and
released it from the mould.
The wing is layed up as follows:- First a thin layer of gel coat, then strips of 300 gram / metre square
chopped strand matt (CSM glass fibre) into the corners (see above picture). Then a full covering of 200 g / m sq
2x2 twill carbon, 300g / m sq csm, and finally another layer of carbon. I used polyester resin
with 1% catalyst in a workshop at around 17 deg C for the main lay up. This gave me plenty of time.
Once the final layer of carbon was on I squeezed out excessive resin with a paddle roller and used pieces of
cardboard to scrape the resin off.
The carbon is very drapable and conformed to the curves of the wing very easily. However
when trying to cut thin strips it would not hold its shape when handled. Carbon tape is better for
thin strips.

 

A badly Fitting Door

The drivers door did not fit too well. So I had to build it up to get a better gap
I drew lines on the door and measured out 50mm from where I wanted the glass
fibre. Then after I had built it up it would be easy to mark the desired line.

 

Building The Door Up.

I stuck a piece of aluminium (not shown here)to the outside of the door, then painted on gel
coat and built up the rear with CSM. This is before the surplus was removed.

 

The Revised Door Gap.

This is the result, a much better door gap. It still
requires final fitting and gapping.

 

Repairing The Door.

The doors were pretty poor, lots of voids behind the gel coat and dry bits
of csm. The big white patch on the door is a very bad dry area. I ground it back
to good glass fibre and then layed in wet csm and finally painted gel coat on top.
I used gel coat to build up the voids on the edges.

 

Removable Carbon Panel.

I layed up a flat piece of carbon on a sheet of glass for the cover for the
hole in the bonnet. This is the underside of the panel showing the carbon weave.
On top is white gel coat.

 

Windscreen Templates.

I used MDF sheet to make templates for the windscreen glass.
Next job is to get the laminated glass cut.

 

Tray For Under The Cut Out.

This is a tray to go under the cut out in the bonnet to catch water.
On the left is an MDF mould, I treated this with release agent and layed
the tray on top. The carbon draped over this shape with out cutting tucks.

 

Front Bumper.

This is the start of the widened front bumper. It is made from a prototype
front spoiler.

 

The Join.

I ground tapers on the join and layed up CSM behind.

 

The Front Bumper On The Car.

The front bumper is designed to fit closely to the front panel.
I will make a mould and lay up a carbon bumper from this pattern.

 

Exhaust Heat Sheild.

This is the panel that goes next to the exhaust by the passenger. The
aluminium is painted with heat resistant insulating paint, then next
to the expansion chamber is a felt like material, the black is graphite insulation
and finally a thin sheet of very reflective stainless goes on top.

 

Heat Shield.

All the insulation materials came from an industrial supplier, much cheaper
than a motorsports supplier.

 

The Finished Heat Shields.

The finished heat shields. The top one is just covered in aluminium backed
glass fibre. This again came from an industrial supplier.

 

The Insulated Expansion Chamber.

Because the expansion chamber acted like a big sound box I have
insulated it with heat insulation. This is held on with bolts.

 

Exhaust Gaskets.

A reader of my website saw I was having problems with gaskets for my
flanges on the exhaust and very kindly supplied a sheet of material.
It is good for 650 deg C and is easily cut with tin snips and holes can be
punched. Thank you very much for helping me out.

 

 

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