Hi
You gave me plenty of ideas to think about. I like idea of using foam core very much and I'd like to do it myself. I can think of two ways of making insert out of foam. CNC machine it (probably expensive) or use liquid foam and mould (obviously smaller because of carbon wall). I have to do a little research regarding use of foam core and learn more about it. Thanks a lot for the reply it was very helpful.
Best Regards
Sylvester

Hi Sylvester

Nice looking car with  a few nods to the ariel atom and  donkervoot going on there!
With regards to one piece you can do it,and there is some technology available from FAR Uk / axon automotive that use a foam core with a braided carbon warp around it.

But if you want to try it yourself you will need to have rohacell or similar core machined to the shape you want then wrap it in your composite and infuse, i would suggest you make a tool or some caul plates to give you a nice surface finish.

To bond  both sides you will need to have a suitable joggle designed into each part or a return flange to give you a decent amount of bond area for joining the two parts. There are plenty of structural bod glues from3M and other companies. 3M 9394 or 9323 are very good for such applications.

Hi from newbie on forum

I am not newbie with composites though, but still could use some help. I designed a sports car with exo skeleton support chassis which I intend to do with carbon fiber (resin infusion). I'd like to make it as one piece (pic 1 left) but I am not sure if it is possible. I hope you could help me to figure it out, if not what would be the best way to glue two pieces together (pics 2 right, 2 left) so they act as one. Attached photo show desired result


Thanks
Sylvester