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Lotus Exige 240 Sport track car parts
Lotus Exige 240 Sport track car parts
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Lotus Exige 240 Sport track car parts
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Hanaldo
Hanaldo
posted 11 Years Ago
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Once that was done, I got into the front lip section:
Then sprayed the whole thing with high build:
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.
Demoulded and polished up:
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Hanaldo
Hanaldo
posted 11 Years Ago
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I then had to remove the inner lining, a prick of a job if there ever was one:
I then removed the inner skin, which freed up around 15-20mm of headspace:
Then moulded the edges back in:
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Hanaldo
Hanaldo
posted 11 Years Ago
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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:
The damage I needed to fix:
Upon getting the grinder out, the damage was more extensive than it first appeared:
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Hanaldo
Hanaldo
posted 11 Years Ago
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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:
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