Car bonnet making - inner structure


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Rocket356
Rocket356
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Hi,

I'm hoping to get into making carbon fibre parts for my car - luggage compartment lid, engine lid, etc. I've watched Carbon Mods and Easy Composites videos online and they seem to cover all the main stuff really well.

I have a question. I'm going to tackle a bonnet first (technically luggage lid - rear engine car). The outer skin looks fairly straightforward, but the steel original also has an inner structure. See attached pictures, which I stole from the internetz. My question is, how can I make both sections separately but then put them together? The outer skin has an inward facing flange making it hard to shoehorn a structure into it once it's made. I could make the inner structure first and then try to add it to the outer shell as I'm making it and the resin hasn't yet cured. The main problem I face is getting the two parts to gel together. Is there a good strong way of bonding two carbon parts together?

Another alternative would be to do away with a separate inner structure and just try to add extra layers into the outer skin in order to put the strength back in. Only problem then is making the mounting points for the bonnet catch and release mechanism, which are all part of the inner structure.

I don't have any of the kit yet so it's early stages, but as hard as I try I can't wrap my technically incompetent little mind around this one...
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20130510_202626.jpg (623 views, 75.00 KB)
Hillman-Imp.jpg (566 views, 336.00 KB)
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