Lotus Exige Front Clam


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Hanaldo
Hanaldo
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Aaaaaand because I'm now in a posting mood; the front bodywork I did for our Exige race car:

https://scontent.fper1-1.fna.fbcdn.net/hphotos-xpt1/v/t1.0-9/12510464_754090401389045_1014295541450088279_n.jpg?oh=581f8960a8f4aed7c19db3132de06fde&oe=57B2D702








Wheel arches flared by 35mm:

https://scontent.fper1-1.fna.fbcdn.net/hphotos-xpt1/v/t1.0-9/12400969_754090434722375_6186128354710743509_n.jpg?oh=5302dc5b86739ed0e2503098c92c5bb4&oe=57BC045D


https://scontent.fper1-1.fna.fbcdn.net/hphotos-xap1/v/t1.0-9/12509509_754090464722372_2092220812819363509_n.jpg?oh=96343179a398bf958dad7875fe29a668&oe=5779BE98


https://scontent.fper1-1.fna.fbcdn.net/hphotos-xal1/v/t1.0-9/21597_754090551389030_4208215315092582167_n.jpg?oh=58c6d9c91c4d0272e349e353304620bf&oe=57735224


https://scontent.fper1-1.fna.fbcdn.net/hphotos-xal1/v/t1.0-9/12509060_755197027945049_935454048942021816_n.jpg?oh=ff8d320e795e954649ff47b858600f1c&oe=57727C62


https://scontent.fper1-1.fna.fbcdn.net/hphotos-xfp1/v/t1.0-9/12410580_756027927861959_6215363780583939522_n.jpg?oh=49dbf5ca59486f393ad427e92b4e8de6&oe=577EF8B7


https://scontent.fper1-1.fna.fbcdn.net/hphotos-xfa1/v/t1.0-9/12376390_756028047861947_3998638707266294953_n.jpg?oh=eab92c04ce64190ed1d0b2bef70bcfaa&oe=577863C3


https://scontent.fper1-1.fna.fbcdn.net/hphotos-xpt1/v/t1.0-9/12645168_761150697349682_1168022580728239627_n.jpg?oh=68057e34ef3f4c66e519eabfa0dcc98a&oe=578006D6


https://scontent.fper1-1.fna.fbcdn.net/hphotos-xpt1/v/t1.0-9/12642454_761150747349677_8631496522627503661_n.jpg?oh=0b8b976a70af79ad636f793d41458127&oe=577AF4A1


https://scontent.fper1-1.fna.fbcdn.net/hphotos-xal1/v/t1.0-9/10436170_785219404942811_4162536039715637739_n.jpg?oh=097264ec1b98e1970da1e809f79379cf&oe=577B76BE


https://scontent.fper1-1.fna.fbcdn.net/hphotos-xlp1/v/t1.0-9/943852_786486901482728_8871403028792424093_n.jpg?oh=b5ceb99e3fe6e53f82b1aa62a8a11adb&oe=57B5C05D


https://scontent.fper1-1.fna.fbcdn.net/hphotos-xaf1/v/t1.0-9/10288767_786486914816060_5653877130849892348_n.jpg?oh=d319bb775dcfe27b9811b2cf1974dd01&oe=577D50D2


https://scontent.fper1-1.fna.fbcdn.net/hphotos-xpl1/v/t1.0-9/10583841_786487001482718_4358172456970746280_n.jpg?oh=2a4cb0222021fb0431be7b6637642a70&oe=57B41FD6


https://scontent.fper1-1.fna.fbcdn.net/hphotos-xpf1/v/t1.0-9/12006174_787969344667817_1056262774617378008_n.jpg?oh=cf60f06c797e661594e181e19e83d41c&oe=57BBE3A2








Original fibreglass weight was 16kg. New carbon bodywork is 6kg, and infinitely stronger and stiffer.
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Hanaldo
Hanaldo
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ChrisR (17/04/2016)
Looking good there Hanaldo, 

6kg, tut tut, that's a bit heavy isn't it?? (only joking)

How flexible is it? will it take a few racing kisses before cracking or is it a one shot deal?


6kg actually is heavy. I built this as more of a 'street-trim' rather than a 'race-trim' piece, simply so that I could show other potential customers what they could expect if they wanted it for a street car. If this one gets broken, I will likely replace it with a heavily-dieted panel of about 2.5kg for the track. 



As for flex and durability, it has been designed to flex in certain directions based on the likelihood of impacts. So if you were to pick it up off the car, it would feel very stiff and not have much flex at all. However when taking a hit from below, such as when it hits the ripple strip, the front of it has been designed to have a small amount of flex to transfer stress to the crash box on the chassis. Of course I couldn't possibly account for every possible impact scenario, so while it may be tougher in one type of impact, it is possibly less so in another type. This will be an evolving design, so if it were to get damaged beyond repair in a certain situation then I will be looking at that and analysing why it happened and what can be done to prevent it again. 

There are also several types of fabric in this layup, which includes Kevlar internally  to hold the laminate together in the event of failure, and black diolen externally in areas prone to abrasion such as the inside of the wheel arches and the bottom lip where it rubs on the ripple strip. I have put a lot of thought into the durability of the panel, more for my own experience and knowledge than anything else. To be honest, it's probably bad business as I will likely never have to replace the thing! 
ChrisR
ChrisR
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Nice, there are a few places in the UK that do racing clams already but with mixed reviews.

Some go for the lightest weight option but crack when you look at them, there are others that over compensate and are two heavy but stiff. - both fail on point impacts

There is one chap that produces a clam that is stiffish for area / aero load but flexible in point loading so you could normally do about 3 races before replacing (unless you bin it!) under normal racing conditions.

My kit car normal bodywork is circa 30kg but the racers is only about 6kg for the entire shell
GO

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Hanaldo - 8 Years Ago
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