Hi!
My customer wants to replace his sliding sunroof with cf flat sheet. He wants it to be quiet stiff but light. I have 3mm soric-like core material, 220gsm cf, 200gsm diolen, wide variety of woven glass clothes and some uni-dir cf 200g 5cm wide cf tape. I could use poly resin as it is uv stable, but I have epoxy also. It will be mounted with rivets to the roof. These are the dimensions : 40cmx80cm or 16inx32 in. How do you suggest to make my layup? I thought about poly resin and carbon/diolen/about 300gsm glass/core/300gsm glass/ cf or diolen. It is for racing purpose.I will laminate it on piece of glass. Please share your suggestions and experience. Thanks for taking your time reading that!
Bye
Wojtek from Poland

~~~Everytime I hear sound of demoulding part I have eargasm~~~

Ok. most car roofs are not flat anyway so once the panel is riveted/bonded into place it will follow the curves of the roof anyway which will add stiffness so a 1mm CF sheet would probably be ok for the size you mention.
If you want to make it really stiff and light I would use 2x200grm - 3mm Soric - 1 450grm or 2x200grm. If you cut the soric 20mm smaller than the roof opening when you vac bag, it will pull the CF around the Soric leaving a 1mm ish thick flange around the Soric but the centre section 4mm ish thick. That way if you trim the part to leave a 25mm flange all the way round the panel will sit almost flush with the surrounding roof. One thing to remember if you use this method you will get a "shadow" of the edge of the Soric showing on the seen surface. If it is for motorsport a perfect cosmetic finish probably isn't necessary.
I will try and post some pictures later that may make things easier to understand.

Warren

Carbon Copies Ltd