Rally Sumg Guard


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Dieseldave
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Hi, Can anyone advise the best way to produce a 10mm thick Carbon Kevlar sump guard for a rally car?
What is the best core material to get the thickness and strenght I need and how many layers of CK each
side.
Hanaldo
Hanaldo
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I wouldnt use a core material for a sump guard. The use of a core is to increase a panels rigidity, not it's strength. While a core can improve a laminates ability to resist impact loading, the types of high energy point loading that you would see on a sump guard very much depend on the strength of the skins, and the core itself would really be a bit of a weak point due to its crush resistance.

For a sump guard, I would be making it 5mm thick solid Kevlar. 5mm is actually probably total overkill, I dare-say 3mm would be fine, but you may as well over-engineer it and get a bit more life out of it. Carbon Kevlar isn't a terrible idea, the carbon would provide extra rigidity that would help spread the loads, however I would only do this on the outer layers, the entire laminate would be a waste as the carbon on the inner layers wouldn't be working as hard. To lay this up, a schedule something like this would work:

2 layers ~200g carbon/Kevlar
15 layers ~400g Kevlar
2 layers ~200g carbon/Kevlar



Dieseldave
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Hanaldo - 5/11/2020 11:24:41 PM
I wouldnt use a core material for a sump guard. The use of a core is to increase a panels rigidity, not it's strength. While a core can improve a laminates ability to resist impact loading, the types of high energy point loading that you would see on a sump guard very much depend on the strength of the skins, and the core itself would really be a bit of a weak point due to its crush resistance.

For a sump guard, I would be making it 5mm thick solid Kevlar. 5mm is actually probably total overkill, I dare-say 3mm would be fine, but you may as well over-engineer it and get a bit more life out of it. Carbon Kevlar isn't a terrible idea, the carbon would provide extra rigidity that would help spread the loads, however I would only do this on the outer layers, the entire laminate would be a waste as the carbon on the inner layers wouldn't be working as hard. To lay this up, a schedule something like this would work:

2 layers ~200g carbon/Kevlar
15 layers ~400g Kevlar
2 layers ~200g carbon/Kevlar



Thank you for the reply. I have another Works car and the Carbon Kevlar sump guard is 10mm thick. For bumpy Irish tarmac rallying the whole 
weight of the car will land on the guard over big jumps so I would be cautious about going any thinner.
at 20 odd layers of cloth it would be a very expensive piece. I might just stick with 8mm alloy.

GO

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