things to look out for when making a car panel


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8900120dd
8900120dd
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Hi guys,
im planning to make a body panel for my car out of carbon fibre, i have some experience in making smaller parts, this will be my first large part BigGrin 
what kind of things would i need to think about?
it will be replacing a plastic panel so it doesnt need to be extremely strong, 3x200g should be okay?
my parts are normally infused with in2 + a layer of gc50 (in mould)
ive been doing alot of research on this topic, but it would be nice to get the opinions of others Smile

1. it would need to be able to withstand (up to a certain degree) stone chips from driving, would infused part with a layer of GC50 be strong enough to withstand smaller stone chips?
2. protection from heat (summer), im assuming most infused parts can withstand hot climates?
3. protection from cold (winter) , how well do infused parts hold up in cold temperatures? 
4. UV protection, what are the options for protecting the part from UV rays?
5. rain/water, do i need to think about protecting the part from rain ?

would appreciate some input

thanks

Steve Broad
Steve Broad
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8900120dd - 10/17/2019 8:35:15 AM
Hi guys,
im planning to make a body panel for my car out of carbon fibre, i have some experience in making smaller parts, this will be my first large part BigGrin 
what kind of things would i need to think about?
it will be replacing a plastic panel so it doesnt need to be extremely strong, 3x200g should be okay?
my parts are normally infused with in2 + a layer of gc50 (in mould)
ive been doing alot of research on this topic, but it would be nice to get the opinions of others Smile

1. it would need to be able to withstand (up to a certain degree) stone chips from driving, would infused part with a layer of GC50 be strong enough to withstand smaller stone chips?
2. protection from heat (summer), im assuming most infused parts can withstand hot climates?
3. protection from cold (winter) , how well do infused parts hold up in cold temperatures? 
4. UV protection, what are the options for protecting the part from UV rays?
5. rain/water, do i need to think about protecting the part from rain ?

would appreciate some input

thanks

I have a little experience with car body panels. I used 2 x 240gsm for a complete front clip, with additional strips along edges. weighs 7kg including front splitter. So for a wing, assuming it is secured along three sides and is curved, I would use 2 layers with 4 additional layers, around 50mm wide, along the unsupported wheel arch edge. But I am obsessed with weight so you may prefer the additional layer.

MarkMK
MarkMK
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It is highly likely that your part will suffer a bit with stone chip damage over time and when using GC50 this will likely manifest itself with quite noticeable but small white-ish marks. 

Using the GC50 will offer better UV resistance compared with making a 'bare' epoxy part but, in many respects, the bare carbon will likely not show the stone chips quite so noticeably (it might be quicker to lose its gloss, though)

Unless you post-cure the part at an elevated temperature first, you will also likely see some evidence of shrinkage after extended sun exposure. However, if post-curing before use, the shrinkage will probably be evident straight away but, at least, it might provide an opportunity to flat the part afterwards and GC50 should allow you to do this and still restore the shine

On balance, the route to creating the most resilient part would be to make it without the GC50, post-cure it and then look to have it sprayed with an automotive quality clear coat, but I appreciate that this might not be a viable option for many. Failing that, just be prepared to replace after a period of time or carry out some maintenance every now and then
GO

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