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Carbon fiber rear deck for wing

Discussion in 'Challenge/GT Cars/Track' started by hezgon, Mar 23, 2016.

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  1. hezgon

    hezgon Formula Junior

    Dec 13, 2006
    281
    Ft Pierce, FL
    Full Name:
    Stan
    #1 hezgon, Mar 23, 2016
    Last edited by a moderator: Sep 7, 2017
    So I installed the Aeromotions rear wing on the 360 Challenge over the winter. From their web page, (Note, you will have to reinforce the deck lid, as shown in the photographs.) Instead of fabricating something like in the first picture, thought to carbon fiber the rear deck lid. This would not only support the wing as suggested, but look unique too. Ran into Larry DiBiase from Formula World Racing, at Road Atlanta during time trials. He will create the carbon fiber overlay for the trunk. My understanding is this is the step to make the mode for the piece, then the paint will be stripped off and the newly created CF piece will be bonded to the deck lid. This is the process he is undertaking to do this work. I will update as he send pictures.
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  2. SoCal1

    SoCal1 F1 Veteran
    Owner Silver Subscribed

    Jun 14, 2011
    8,630
    SoCal LA/OC/New Mexico
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    Tim Dee
    #2 SoCal1, Mar 23, 2016
    Very cool
     
  3. hezgon

    hezgon Formula Junior

    Dec 13, 2006
    281
    Ft Pierce, FL
    Full Name:
    Stan
    #3 hezgon, Mar 28, 2016
    Last edited by a moderator: Sep 7, 2017
    Next set of updates:
    The first picture is the surface coat placed on the car to obtain an exact replica of the Ferrari hatch.
    Second picture is the layup under full vacuum. The black dots is resin bleeding off to make the compaction perfect or the resin to carbon 40 – 50%
    Fourth picture is the mold with metal bracing so not to distort in the post cure process.
    Next two pic is the mold pulled off the car. Post mold work is needed to “clean” the mold and prepare for making parts. The “red” is special clay needed to seal areas between car and flanges.
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  4. Schatten

    Schatten F1 World Champ
    Owner

    Apr 3, 2001
    11,238
    Austin, TX
    Full Name:
    Randy
    #4 Schatten, Mar 28, 2016
    Very very cool!
     
  5. hezgon

    hezgon Formula Junior

    Dec 13, 2006
    281
    Ft Pierce, FL
    Full Name:
    Stan
    #5 hezgon, Apr 1, 2016
    Last edited by a moderator: Sep 7, 2017
    Next steps from Larry:

    "The hatch is all prepped for bonding, completely stripped. I must say the paint on the Ferrari is absolutely incredible. I had to use 35 grit sand paper ( very course) and an orbital sander to take the paint off. The Italians really have that down. I have included a picture with the paint stripped off. I did not use chemical to strip due to the residue on the aluminum…. I wanted it perfectly clean."

    "I will be polishing the mold tomorrow and making the carbon part. Once it cures overnight. It will need to post cure in an oven to raise the operating temp of the resin thus allowing it to “take heat” when on the car. Following this step, I will be trimming and fitting the part followed by a spraying a UV clear coat and finally bonding to the hatch. "

    "I hope to be completed by Sunday."
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  6. hezgon

    hezgon Formula Junior

    Dec 13, 2006
    281
    Ft Pierce, FL
    Full Name:
    Stan
    #6 hezgon, Apr 5, 2016
    Last edited by a moderator: Sep 7, 2017
  7. hezgon

    hezgon Formula Junior

    Dec 13, 2006
    281
    Ft Pierce, FL
    Full Name:
    Stan
    #7 hezgon, Apr 8, 2016
    Last edited by a moderator: Sep 7, 2017
  8. hezgon

    hezgon Formula Junior

    Dec 13, 2006
    281
    Ft Pierce, FL
    Full Name:
    Stan
    #8 hezgon, Apr 10, 2016
    Last edited by a moderator: Sep 7, 2017
    tifosi101 likes this.
  9. stevecomp

    stevecomp Formula Junior

    Mar 1, 2013
    743
    South Australia
    Full Name:
    Steve
    #9 stevecomp, Apr 13, 2016
    Why not just remove the alloy skin and bond on the part you made to the frame rather than adding weight to it with an over skin?
     
  10. ldibiase

    ldibiase Rookie

    Mar 23, 2016
    1
    #10 ldibiase, May 18, 2016
    Hello Steve,

    I looked at doing exactly what you are referring to. The issue here is it is almost impossible to remove the aluminum deck without destroying the sub structure. In essence you will be rebuilding the whole rear deck which consists of much more work. The total weight of the CF part is approx 1.9 pounds.

    The carbon part is made of 2x2 twill 3k, 3 oz fabric, vacuum bagged to debulk. and post cured.

    I hope this helps.

    Larry DiBiase
    770-331-8204
     

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