Lotus Exige 240 Sport track car parts


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Hanaldo
Hanaldo
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Once that was done, I got into the front lip section:

https://scontent-b-hkg.xx.fbcdn.net/hphotos-xpa1/t1.0-9/603126_514745448656876_3599537435444844004_n.jpg


https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/10553414_514745661990188_2127488193397578545_n.jpg?oh=c884b20ae7beacfbd1b501d328d88f0a&oe=548220EB&__gda__=1416503095_d24bdc905dc4753204341818bc93868a


https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xap1/t1.0-9/10522553_515729385225149_7756935395028206891_n.jpg


https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/1043963_10152145088522541_2951036913734143675_n.jpg?oh=bc097a9c41e7fc556dc6587928ffb647&oe=54621A0C&__gda__=1415306598_a25cabb0a769073de906ad14f4547085




Then sprayed the whole thing with high build:

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/1508536_519042238227197_6223835951355011095_n.jpg?oh=45d39f0a29ea6ef34e77c61483840f58&oe=54644583&__gda__=1416164819_aa7dba0da5443f3a90821c9c1981e2d8


https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10403461_519042254893862_3183361049815855041_n.jpg?oh=82c1cf27a1bc610f155807be7c22fb50&oe=546DE79C&__gda__=1415776036_0884929c6bf6a5f1d10dacbd1bf39fa0




Unfortunately I don't have too many photos of the mould making process, but it was pretty straight forward. Done in 2 skins obviously, and inner and an outer. The outer skin was made slightly more complex because of the undercut between the front of the scoop and the lip I had just moulded on, so this necessitated a split mould for this section. Thanks to brainfart on for bouncing some ideas around with me on here for the best way to do that split.





https://scontent-a-hkg.xx.fbcdn.net/hphotos-xpa1/t1.0-9/10600520_525954134202674_8464615101123954787_n.jpg


Demoulded and polished up:

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xfa1/v/t1.0-9/10570399_525954187536002_1844900375897228597_n.jpg?oh=79b16e55927b434515461bca81b435cc&oe=547EF1C7&__gda__=1416708593_a3a46b8223021788f867a249b47afa81


https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xaf1/t1.0-9/10491994_525954164202671_2067474959021687385_n.jpg
Hanaldo
Hanaldo
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I then had to remove the inner lining, a prick of a job if there ever was one:

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10561700_512437702220984_7325882216020956927_n.jpg?oh=9a31e8eeab71c624805d5c3ae93c206a&oe=5473BDE4&__gda__=1415347036_bc471d78df25890a7b0121698cb69904


https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xfp1/t1.0-9/10524681_512437725554315_7093526467114896031_n.jpg


https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-xaf1/t1.0-9/10410988_512437762220978_2468683588650279791_n.jpg


https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/10479183_512437798887641_5809626252307493714_n.jpg?oh=48a97957c5092ab402accd57c6fac4fc&oe=54725B16&__gda__=1415843487_22f3f94ee07f1b4299d6e112231c5c93




I then removed the inner skin, which freed up around 15-20mm of headspace:

https://scontent-b-hkg.xx.fbcdn.net/hphotos-xap1/t1.0-9/10452344_512862242178530_1608079541626812749_n.jpg


Then moulded the edges back in:

https://scontent-a-hkg.xx.fbcdn.net/hphotos-xaf1/v/t1.0-9/10491158_512862272178527_7807553627180772051_n.jpg?oh=dd0bf3f32977fa7fccc83b5a92c4cc8d&oe=546B9309
Hanaldo
Hanaldo
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The next part I built was the roof panel. This was a pretty major project, given the original needed some repairs and the customer wanted some pretty extensive modification. Basically the guy is a giant who chose to drive the smallest car he could find, so his head touched the roof while driving which is obviously a safety concern, so I had to find some head room. The car also has an aftermarket windscreen which was smaller than the original, so there was a 1.5" gap between the roof and the windscreen; no good for aero or aesthetics. So I needed to mould a lip onto the roof that brought it down to sit under the windscreen seal. And finally, the original fibreglass roof weighs ~16kg and was the most rickety OEM panel I have ever seen which, given the power output of the car, caused it to fly off the car numerous times at the track.

This was the original how it was given to me:

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpa1/t1.0-9/10516840_512437528887668_2231393706648191725_n.jpg


The damage I needed to fix:

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10421566_512437558887665_3868915259443331791_n.jpg?oh=8e127533a193af49bc48b1dc1ab576e1&oe=54600CDC&__gda__=1416497508_67e529b289c1aae9bf2240a3b3f86a65


https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10421566_512437558887665_3868915259443331791_n.jpg?oh=8e127533a193af49bc48b1dc1ab576e1&oe=54600CDC&__gda__=1416497508_67e529b289c1aae9bf2240a3b3f86a65



Upon getting the grinder out, the damage was more extensive than it first appeared:

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xap1/t1.0-9/10441122_512437615554326_5072967760175046139_n.jpg


https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/10314684_512437658887655_9199512504995624674_n.jpg?oh=cbfea3d34d698f2220491c7ea443eb70&oe=547DA27D&__gda__=1416318625_a4542b5aa9e3dcc4d1cece9c12e87029
Hanaldo
Hanaldo
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Hey all,

Having recently started my own composites business, I found myself doing a large amount of work for a local workshop/race support team here that deal with all-out track cars (and people with entirely too much money). The workshop have got so much work for me to do that I don't really have time to do anything else at the moment, but over the last month or so my main project has been the Lotus Exige that they have.

Long term, the customer wants to build the entire thing barring the chassis from carbon fibre. Fortunately my job is made easier given the car is basically a block of aluminium for a chassis and the rest is fibreglass bolted on, so everything is designed to work with composites. The first part I made for them was a simple dash mount for the Motec C185 digital dash, which I had to design and build from scratch:

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xaf1/t1.0-9/q81/s600x600/10530663_510053649126056_8426371776505895906_n.jpg






https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xfp1/v/t1.0-9/10501647_510053835792704_7622404527679314892_n.jpg?oh=553736836e41d1908ebdd5d8a1d42f44&oe=546F796A&__gda__=1416473315_1547edb86220300980b1b7784427fb46


https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-xap1/t1.0-9/10526027_515264805271607_6578906006876668366_n.jpg


https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/10489950_518527658278655_1061944899208211983_n.jpg?oh=bf2054192343c07a72d5fcb24bc46a38&oe=547D66A9&__gda__=1415533507_0062c379bbb7ff981791526101dc2353




https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xaf1/v/t1.0-9/10563046_529450900519664_7497071240877275634_n.jpg?oh=5129971c6ced82ee8930a20219abf94a&oe=54704536&__gda__=1417229447_d2639e96bed4146789531ffa7c87a8ef


https://scontent-a-hkg.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10501663_529450930519661_4755183550705723864_n.jpg?oh=2e48617630f1c0564dbece870d35be22&oe=5479723B
GO

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