AB Performance Sabre Racer - Complete Bodywork in Carbon


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Ragged99
Ragged99
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Hi Guys,

I thought I'd pop up and show you what my mate Tim and I are doing with the Easy Composites systems in our garages.

We're what Enzo Ferrari called "Garagistas"  in that we both own AB Performance Sabre race cars, and we build, modify, and prepare them to run  in a race series called  RGB with the 750 motor Club.  In short we're clubman racers and we like building stuff.

Our cars are powered by bike engines, and we aren't allowed wings. so we need to generate aero efficiency from the main body of the car. 

Tim is in mid build of his new Sabre and wanted non standard bodywork to try and improve the aero efficiency, and I wanted different bodywork on my year old Sabre as the car is currently too big to fit in my garage without partially disassembling it, which is a right pain when you arrive home at midnight after a weekends racing.  Also I'm  a big lad and ultra lightweight carbon  bodywork will help me get down to the minimum weight limit for the car and driver.

So we basically decided to build our own bodywork from scratch.   I'd done some small scale fibreglass, buck and mould building in the past on a former car, and we were pretty impressed with the resin infusion process so decided to give the Easy Composites system a try.  We even ran a test infusion process on my glass coffee table top ;-) to make some flat carbon panels.

Although we've never tackled anything of this size, we're doing the full spectrum of build a buck, surface it, then make a mould, them carbon resin infused parts.

So for the last couple of months we've been building a buck around Tim's partially complete chassis.  Well in fact Tim has 90%  of the work and I'm chipping in at weekends.

The buck has been built from timber, 3mm mdf board which is nicely flexible for simple curves, filler and foam. and we're now at the pattern coat primer stage.   We've learned a lot along the way, but basically we've followed the video tutorials and have just scaled up the processes.

Full details are on Tim's website at www.hoverd.org

Details of my racing are at www.rgbracer.com.. and the main AB performance website is www.abperformance.co.uk.

But to whet your appetite here's a picture of the buck in pattern coat.
http://www.hoverd.org/Tim/ttcp/wp-content/uploads/2014/01/Black-again.jpg

Cost to date in materials for the buck, pattern coat, foam etc is about 500 quid, although I've just spent about 600-800 on Unimould materials + CSM  for the mould making stage.

Cheers

Adrian Moore
Edited 11 Years Ago by Ragged99
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Warren (Staff)
Warren (Staff)
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Hi Tim,

To solve your flange issue, in an ideal world I'd say lift the plug off the body (if stiffenough) so you have unrestricted access all round.  However, this may not be as practical or easy as it sounds in some cases!!!

However, if you can't do that, its not the end of the world. You just have to go back to think of the purpose of the flange where you have located it. For most processes a small flange of sorts is necessary to give a neat edge to the part so you can trim it and also it helps prevent mechanical lock.  For vacuum processes, it is a little more important as the flange is often also used as the bagging flange and you would need the space to fit the bagging stack so it seals well to the mould flange.  Extra space is particularly important on the vacuum port areas and the resin feed side of the mould.

So not withstanding that, you can be quite creative with fluted signboard when making flanges so you just have to do it the best you can where things are tight.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant
Teem
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Warren,

Thanks. However, the plug relies rather completely on the chassis for support and, as such, it'd be hard to separate! However, Adrian and I had a chat through at the weekend and I think we're clearer now on where the flanges should be. We doubtless have some questions about them, though, which can wait a while.

What we did do was to make the plug green by adding some pigment into the final coat of pattern primer. Hopefully there's just another rub-down requires which I reckon is about 30 hours work. Gulp...

http://www.talkcomposites.com/Uploads/Images/95b8481f-f8f7-4844-8338-33ef.jpg


Tim
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I thought you might like to see the moulds that resulted from all this:

http://www.hoverd.org/Tim/ttcp/wp-content/uploads/2014/03/Left-rear-large-mould-001.jpg


and the whole lot:

http://www.hoverd.org/Tim/ttcp/wp-content/uploads/2014/03/Moulds-in-place.jpg


The mould release, a combination of Easylease and mould release wax worked brilliantly.

Lots more detail on the website: http://www.hoverd.org/Tim

Tim
GO

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