Carbon Fiber Front Reinforcement Panel

[bigjae46]

v1 is done!









I have some nutserts on the way to mount the underbody panels for the transmission.

This came out thicker than the OE part so the underbody panels won't slide in. One area for improvement.

I torqued the bolts multiple times, no galling or marks in the carbon. Not concerned with damage around the bolt holes. Galvanic corrosion could be an issue since carbon is electrically conductive. So I may add titanium washers at some point.

I did have to enlarge one bolt hole for the control arm bushing. Same hole I had to enlarge for the OE panel.

I bolt U-channel for the splitter to the front. I should have left more material there.

I would like to make it lighter. Some possibilities is using a core which would also make it cheaper to build. Could apply less layers with added reinforcement in targeted areas. The problem is I'm not 100% sure what those areas are.

Anyway...Proof of weight.

Carbon 4.8 lb



Aluminum - 7.4lb



planned v1.1 changes

- lay up the trans cover mountings with fewer layers so the label can slide in

- extend front of plate to aid with mounting a front splitter

- reduce weight by using a core material or targeted reinforcement


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[Cronenberged]

You could add a divinycell foam for extra rigidity and to cut some weight. Looks good bigjae46

[bigjae46]

You could add a divinycell foam for extra rigidity and to cut some weight. Looks good bigjae46

The contours would be an issue. If I do use a core, I'd use a soric core but it would have to work around all of the bolt holes and openings.

[Arith2]

How did you get education on making carbon fiber parts? All online?
If there are kits/homemade materials that are relatively inexpensive I would love to try my hand at some small stuff.

Great work!

I'm have not dabbled in this yet so not an expert by any means however this three part series actually was really helpful in explaining how to.

(67) How to Make a Carbon Fiber Car Bonnet/Hood - Part 1/3 : Making the Mould - YouTube

[eacmen]

Subscribed. Awaiting the facebook marketplace link. 😂🤘😎

[bigjae46]

I'm have not dabbled in this yet so not an expert by any means however this three part series actually was really helpful in explaining how to.

(67) How to Make a Carbon Fiber Car Bonnet/Hood - Part 1/3 : Making the Mould - YouTube

Those videos from Easy Composites are where I started. Over the past 6 months, there is a lot more info on the internet. The hard part has been knowing what to buy. Simple stuff like the gum tape...there's a specific gum tape you need to get.

By far the worst part is cutting/sanding. You need a respirator and something to collect the dust. I only cut/sand this stuff outside of my garage.

[Arith2]

Those videos from Easy Composites are where I started. Over the past 6 months, there is a lot more info on the internet. The hard part has been knowing what to buy. Simple stuff like the gum tape...there's a specific gum tape you need to get.

By far the worst part is cutting/sanding. You need a respirator and something to collect the dust. I only cut/sand this stuff outside of my garage.

There was literally a small series of a guy going through everything to buy but I have no idea when I watched and how I found the series. It was back in 2018 or something. He had a 7 or 9 part series on supplies, building the mold, and doing the job. One day I hope to run across it so it can also be posted. I spent about an hour looking today. What was the overall cost of doing this job including getting all the starter supplies and tools?

[bigjae46]

There was literally a small series of a guy going through everything to buy but I have no idea when I watched and how I found the series. It was back in 2018 or something. He had a 7 or 9 part series on supplies, building the mold, and doing the job. One day I hope to run across it so it can also be posted. I spent about an hour looking today. What was the overall cost of doing this job including getting all the starter supplies and tools?

Just this one part - $900 plus the cost of the part. Need stands, clamps, a vacuum pump, resin trap…it’s a ton of small stuff. Plus safety gear. A good respirator, gloves, coveralls or tyvek suit.

I’ve worked with fiberglass before. Probably want to start hand laminating FG stuff first. It’s a lot cheaper to learn what working time means with polyester resin and FG.


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[Arith2]

Just this one part - $900 plus the cost of the part. Need stands, clamps, a vacuum pump, resin trap…it’s a ton of small stuff. Plus safety gear. A good respirator, gloves, coveralls or tyvek suit.

I’ve worked with fiberglass before. Probably want to start hand laminating FG stuff first. It’s a lot cheaper to learn what working time means with polyester resin and FG.


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Yeah the guy mentioned practicing with fiberglass first because it is not likely a first timer will get it right. This is an art in and of itself.

[jet_dogg]

What was the point of this again?

[eacmen]

What was the point of this again?

Being awesome.

[Cronenberged]

What was the point of this again?

Every pound counts, and becauseracecar

[bigjae46]

What was the point of this again?

To make you ask the point.


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[pawa_k2001]

Love it! If you ever consider selling these, I may be interested.

[TwoD]

Very cool, love seeing DIY projects like this!