cloudy
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| posted on 28/1/08 at 02:56 PM |
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OK will remember that 
James
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sgraber
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| posted on 28/1/08 at 04:34 PM |
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Just don't try to shape that expanding foam with a hot-wire as it lets off very noxious fumes. A serrated blade and sanding block would be the
way forward.
Best of luck and congrats on a fine design it very attractive and from all appearances should be a successful design.
Steve Graber
http://www.grabercars.com/
"Quickness through lightness"
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Fred W B
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| posted on 28/1/08 at 06:40 PM |
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I used polyurethane foam, with a density of 32 kg/m2.
The "surform" tool works great on foam
Cheers
Fred W B
 
body23
[Edited on 28/1/08 by Fred W B]
You can do it quickly. You can do it cheap. You can do it right. – Pick any two.
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cloudy
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| posted on 28/1/08 at 07:02 PM |
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Thanks guys, all good info 
I take it you coat the foam when you have finished. Then you lay up straight on that which gives you the mould?
James
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Schrodinger
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| posted on 28/1/08 at 09:02 PM |
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quote:
Originally posted by cloudy
I've only tested it up to 3mm wall tubing, I suspect thats close to it's limit as the screwjack becomes very hard to turn!
Does anyone know a supplier for the foam commonly used for hand shaping moulds intended for glass fibre layup?
I'm going to take a crack at building a CF/GRP composite bonnet!
James
[Edited on 28/1/08 by cloudy]
http://www.cfsnet.co.uk/ sell it look in the catalogue under foams and core materials
Keith
Aviemore
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nitram38
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| posted on 28/1/08 at 09:22 PM |
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quote:
Originally posted by cloudy
Thanks guys, all good info
I take it you coat the foam when you have finished. Then you lay up straight on that which gives you the mould?
James
You will need a smooth surface on your "buck", plus plenty of release wax. Also you will need to work out if the panel will come out of
the mould. This means breaking it down into smaller moulds by creating flanges to join the mould before laying up.
It is a long and time consuming job!
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Fred W B
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| posted on 29/1/08 at 06:24 AM |
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WRT surfacing the plug I have been advised by a very experienced pattern maker to proceed as follows:
Cover foam with a layer of csm and resin, and sand.
Coat with body filler, sand, finishing with 180-240.
Spray with a purpose designed product called Durabuild
duratec
(only need the primer) and sand, finishing with 1000, then cut and polish.
Cheers
Fred W B
[Edited on 29/1/08 by Fred W B]
You can do it quickly. You can do it cheap. You can do it right. – Pick any two.
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cloudy
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| posted on 30/1/08 at 10:31 PM |
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Managed a 32kg weight saving by swapping to 15" superleggera alloys totalling 13.5kg (they have some cheap heavy rubber on at the moment)
I'm hoping to get that down to 12kg with a sensible rubber choice...
[Edited on 30/1/08 by cloudy]
[Edited on 30/1/08 by cloudy]
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ZEN
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| posted on 31/1/08 at 07:04 PM |
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The OZ Ultraleggera weights just 5.44kg/piece and are the lightest 15" alu wheels. At least that is stated in POWER TUNING MAG.
[Edited on 31/1/08 by ZEN]
[Edited on 31/1/08 by ZEN]
My YouTube channel Cars, bikes - track days, motorsport, sim racing and more.
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cloudy
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| posted on 31/1/08 at 10:21 PM |
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The superleggera's are lighter, but you cannot buy them anymore - this was a well looked after set from ebay...
superleggera 7x15 = 4.9kg
[Edited on 31/1/08 by cloudy]
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ZEN
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| posted on 31/1/08 at 10:27 PM |
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Lighter than Ultraleggera??
My YouTube channel Cars, bikes - track days, motorsport, sim racing and more.
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cloudy
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| posted on 1/2/08 at 12:34 AM |
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yup
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cloudy
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| posted on 2/2/08 at 03:05 PM |
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Pushed her outside today to see how it's looking
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nitram38
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| posted on 2/2/08 at 03:33 PM |
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Looks great to me!
Seems you will beat me to the finish first!
I'd better get going to salvage some pride 
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cloudy
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| posted on 2/2/08 at 03:50 PM |
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Not sure about that!, I've got a helluva lot to still do - it's the fiddly stuff that takes the time as I'm sure you know 
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nitram38
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| posted on 2/2/08 at 03:56 PM |
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quote:
Originally posted by cloudy
Not sure about that!, I've got a helluva lot to still do - it's the fiddly stuff that takes the time as I'm sure you know
That is where I am at right now.
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kikiturbo
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| posted on 2/2/08 at 05:45 PM |
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may I kindly ask you, and nitram of course, the weight of your chassis.
I can't seem to decide how light is light enough in my build... and while the FEA numbers are OK, I sometims want to keep slightly thicker
tubing around the passenger compartment then strictly necessary.
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cloudy
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| posted on 2/2/08 at 09:52 PM |
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I must admit I did not weigh it bare, Can probably come up with a guess based on tubing length if you'd like?
Incidentaly weighed it today at 294kg - looks like I need to do some work on the heavy sierra components at the rear....
James
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ZEN
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| posted on 2/2/08 at 10:15 PM |
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Nice progress!
Here are some styling ideas
[Edited on 2/2/08 by ZEN]
My YouTube channel Cars, bikes - track days, motorsport, sim racing and more.
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cloudy
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| posted on 2/2/08 at 10:56 PM |
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oooh interesting, any idea where I can find more info?
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Alan B
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| posted on 2/2/08 at 10:57 PM |
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Wow..never seen the Kirkham Rush before...soooo much like what I'm doing except for only being 2 seats of course...
[img][/img]
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ZEN
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| posted on 2/2/08 at 11:00 PM |
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quote:
Originally posted by cloudy
oooh interesting, any idea where I can find more info?
http://www.kirkhammotorsports.com/custom/rush_index.html
My YouTube channel Cars, bikes - track days, motorsport, sim racing and more.
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nitram38
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| posted on 2/2/08 at 11:52 PM |
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quote:
Originally posted by kikiturbo
may I kindly ask you, and nitram of course, the weight of your chassis.
I can't seem to decide how light is light enough in my build... and while the FEA numbers are OK, I sometims want to keep slightly thicker
tubing around the passenger compartment then strictly necessary.
Not weighed it yet, sorry
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kikiturbo
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| posted on 3/2/08 at 02:48 PM |
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ok nitram, no problem, I am hovering around 50 KG, and am not comfortable in getting it lower than that..
I'll cheack what different sanctioning bodies say about tubing size vs. vehicle weight next..
[Edited on 4/2/08 by kikiturbo]
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kikiturbo
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| posted on 3/2/08 at 02:49 PM |
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quote:
Originally posted by cloudy
I must admit I did not weigh it bare, Can probably come up with a guess based on tubing length if you'd like?
Incidentaly weighed it today at 294kg - looks like I need to do some work on the heavy sierra components at the rear....
James
oh, yes, an estimate based on tubing length, size and wall thickness would be great thanks..
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