Dear Sirs,
               I am constructing a single seater race car for sprints and speed hillclimbs part of  which involves an aluminium alloy monocoque which I wish to stiffen with a honeycomb,or similar,core. Whilst the major part of the monocoque is straight lines and should present little problem, there is a section involving a single,gentle curvature.Is it possible to curve an aluminium honeycomb core to pre-curved alloy panels? or should I instead consider foam core?
Any help or advise would be appreciated before I commit the design to the metal.
Thanks in advance,
Dennis Troman

Hi Dennis,

It sounds like an interesting project.

If the curve that you need the aluminium honeycomb core to comply to is relatively gentle (for example the inside of a wheel arch would not be a problem with a 10 or 15mm honeycomb) then you shouldn't have any difficultly working with aluminium honeycomb. The cells are relatively flexible until the honeycomb is bonded into place meaning that within reason, most steady contours can be accommodated.

I hope this answers your question and gives you the confidence to work with this material in your design.

All the best, Matt

Matt Statham
Easy Composites / Carbon Mods - Technical Sales