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Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car

Posts: 2955
Reg: 04-2006

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Monday, November 14, 2011 - 09:23 pm, by:  Ben Lipman (Ben12a)

Lets just wait and see what it looks like on the inside before getting too exited. I just hope it parts OK. I have spoken to the local fibreglass shop about buying in bulk- at this rate I might actually get through a 30kg roll (about 200m of 450gsm chopped strand matt). There is about 10m of matt and tissue in the mould alone. The mould is not as thick as some I have seen on the net- half an inch (12.7mm) is a lot of fibreglass! FGI literature suggests 2 times as thick as the part you want to produce. It has been suggested two layers of 450 gram matt is sufficient for a front spoiler. I have about 4-5 layers in the mould depending on the location. Some areas around the bracing etc have upto 7 layers.

The front spoiler is very deep. The undertray you very generously gave me (never did sort you out for freight...you owe me an email, Andrew) is 600m deep give or take. The spoiler is closer to 850mm deep so I need to marry the undertray to the underside of the splitter.

I could (and probably will) extend the undertray to fit the spoiler, but I still need a return of some sort to give me somewhere to attach it to. I need to cut and shut the undertray as mine is nowhere as wide as your car.

I spent some time looking at the doors last night. The outside moulding is a no brainer- simply take off the exterior door handle and glass over the lot. The inside is much trickier. The way I see it is there are two choices:

1. Use all the factory hardware and therefore there is a need to build some additional strength into the striker plane and hinge mounts. I think significant reinforcement is needed in the hinge area due to the massive hinges and the forces they could be generating.

2. Bin the factory hinges and make something custom based around a drop in gate hinge design. This would eliminate the spring forces from the factory hinge as well as save what I guess is a significant amount of weight. I could also easily remove the doors should the need arise. Unfortunately it also adds a fair degree of complexity to the job.

The missus just looked at me like I was insane when I mentioned I might be doing the doors as well. It might take some time as I need to make sure I don't spend too much time on the car. Gotta get this work/family/sports/hobbies balance just right...

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