How to Build Race Car Rear Wing Moldless Fiberglass Foam Core Composite Construction
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- เผยแพร่เมื่อ 30 ก.ย. 2024
- How to build / fabricate / fab / make an adjustable rear wing for a Formula 1000 race car with a foam core cut on a homemade hot wire foam cutter, laminated with a stressed skin of epoxy fiberglass. Includes making rear wing endplates (end plates?) with aluminum hard mounting points, aluminum adjustment plates for the airfoil, and aluminum bases to mount the endplates to the diffuser.
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you think it would work well to 3D print a hollow very thin positive mold for a wing and then lay carbon fiber over it exactly like you did here?
Dunno if this would help you, but we did an experiment in our FSAE project where we printed abs parts with 50% infill and 1.5mm perimeter wall. Then laid carbon fiber over it. It worked out but we went with nomex core and molding process, in the end. Nomex cores soak up resin and have better adhesion with the composite fiber layers than parts with carbon fibre skin over 3d prints.
All your neighbors must think your "The Mad Scientist." I had one of you guys when I was a kid, he built custom RC planes.... Wonderful video. I always admire the patience some humans possess.... :--)
Great video I made a rc F1 car with sonarpanels For school and your tips For making the spoilers were Great.
Thanks for the support!
I’m planning on building my own, where did you get the mould?
What strength can a wing achieve using this type of technique with styrofoam filling? Can it withstand few hundred kilograms of downforce or above 250 km/h?
it so cool and thanks for teaching people how to do it yourself
Very inspiring and the attention to details considering you worked everything on your own. What brand resin did you use?
hello sir how can we made epoxy resin hand made or you just bought please can you tell me sir
Ok, so you spend many thousands of dollars on building a car but you don't even invest in a 50$ microphone, so it doesn't sound like you recorded it on a toaster
Which kind of foam did you use for your wing manufacturing and till which temperature it holds upto
Wow! What an amazing peace of engineering you have there.
Really surprised you are only orienting the glass on x and y axes. ±45° orientation adds a LOT of strength and prevents distortion; you might look into that. Also, vacuum bagging would reduce excess epoxy and the epoxy/glass ratio is really important for strength. Honestly, nice job but pretty much technically oblivious as regards to strength. I write this as an areospace composite tool designer.
You wrote this without much sense of economy, but thanks for the heads up
Wait, that foam are gonna melt if it touch resin isn't it?
Please tell me that this thing is at least going to see some test session track time relatively soon.
Even better, I'd love to see you get it in race trim, and actually do some competition laps before the season is out.
What's your current (realistic) timetable for both those milestones?
+hippyjason We're planning another test day later in April, 2016. If the car feels right we'll crank up the speed, but still not going for a track record. Competition laps are problematic, as it's the only Formula 1000 car in Thailand.
+Ludemann Engineering Wow. Ok, don't they at least have some kind of formula libre class out there? Or at the very least, a run-what-ya-bring class?
I take it your long term goal, then, is to make and sell a sufficient amount of these things so that there will eventually be enough F1000 cars in Thailand to be able to make a decent enough sized grid, so that you can then have a viable class/race series?
What's the biggest-sized formula car that they already currently race as a series over there -Formula Ford? Does Thailand have a SCCA equivalent sanctioning body?
Sorry for all the questions, but this is a completely fascinating subject to me. :)
Auto racing in Thailand is controlled by the Royal Automobile Association of Thailand (raat.or.th). There's such a big language barrier that I don't really know what classes are officially sanctioned. I think they have something like Formula BMW and Formula 3. But you're right, we want to sell enough cars to have races in Thailand.
What was the weight of wings along with endplate?
Where’d you get the material for the mould
Nice work. S1223 profile?
+OpticalNZ Good guess! S1223 was one of the profiles the designers started with, but it was evolved further.
wooooooooo booooooyyyyyyyyy that's astonishing
Thanks for posting this way back when.. It's 2021 and I'm just getting started. Epoxy foam and carbon fiber for my motion simulator frame. This has been one heck of great channel to learn stuff. DMAX motion sim ch
Wow excelent proyect is an my dreams built an race car congratulations for create is fantastic 👍👍👍👍👍👍👍🏎🏎🏎🏎🏎
I am shocked that the epoxy doesn't dissolve the Styrofoam. Is it special Styrofoam or epoxy? awesome work by the way, we are building our own car from scratch, swing by our channel, I would love to hear what you think. I am very happy I found your channel. Keep the videos coming. Best Matt
I only have one choice of styrofoam and one choice of epoxy resin here, so I have to assume they are both generic. They work fine together. Good luck on your project!
Ok, Thanks for doing the videos. Keep making them.
Best Mat
Styrofoam is dissolved by polyester resin (contains styrene). Afaik epoxy doesn't emit solvents while curing. So it works with polystyrene.
Glad I found your channel tonight. I have an old Reynard FC and I am building a diffuser right now. And, I would like to build some foam core/CF wings next. Thanks,
great video and even better end result. A lot of the parts you make require you to fiberglass on top of cured Epoxy resin is sanding enough to get a good adhesion to the cured Epoxy primer? with polyester resin it has a chemical bond and softens the cured layer to join them. (ps don't try polyester resins with polystyrene its a fail)
Nice Job, The "Priming and sanding, Priming and sanding" is what separates the Men from the boys.. It ain't done till the finish looks perfect.
hello James,
i was watching this video of yours again i noticed that you said something about a study for the rear wing with finite element analysis, so i was wondering from where did you get the cloth modulus strength data please ?
i would really appreciate your help about this, because i am making my final project for master degree. Included in my project design and study of racing car wings which will be made from fiberglass
Hiya, great great GREAT video. I have two questions, what thickness cloth are you using and how do i go about making a styrofoam mold ? Thanks a lot !
Could you use a 3D printer to make the part and would the part be stong enough. Cheers.
Great work! But one concern, the wings were made with no mold, is it problem when you damaged them during the race? need replacements?
Why its not from carbon fiber?
exo-xpensivo.
Expensive.
Nice detailed work, how much does the rear diffuser, wing assembly weigh please?
Why does the foam don't melt with the fiberglass resin? I try that once and it melted the foam
They used epoxy resin, not polyester (fiberglass) resin. Polyester resin is the type that will melt styrofoam.
what is the compposition of epoxy resin that you use on foem and fiberglass?
Nice!
so awesome!! how much do foam cores cost to make roughly? Would love to start creating my own parts and trying a hand at aero.
now, go drive/crash it and see if it holdes. I see the process, but I need to believe.
could you please share the epoxy composition with me? thanks!
you now have another subscriber thank you for all your videos
Why didnt the epoxy eat through the styrofoam?
How much resin do you need for that size wing?
any video for carbon fibre foam core formula racing wings
I'm kind of surprised that you're not using any kind of filler or similar on the styrofoam first for a better finish, and that you're also not vacuum bagging your parts.
The epoxy resin fills in the styrofoam just fine, and I don't see any foam texture on the outside. I'm don't think vacuum bagging will work on a wing like this as it will crush the trailing edge, but I use it on other parts like the wing endplates, diffuser strakes, and the floor.
Can a monocoque tub be built this way using denser foam and thicker woven rovings? without using carbon fiber and RTM?
You could do that, as airplanes have been built this way. The problem, as always, is the design & implementation of hard mounting points.
Hi what grade of foam are you using here?
Great video...thank you!
Added lightness 😂😂😂😂😂woooow
Great song by shane and shane
that is exactly I want to learn
so u leave the foam in there? ok I was gonna say how in the hell is he gonna get the foam out of the inside lol ...this gives me ideas for body kits etc .....subbed sir :)
Yes, the foam stays inside. It makes the wing stronger by holding the fiberglass in place, resisting long-column buckling.
Amazing work!
What are the reasons that you didn't use carbon fiber for this? Strength difference, weight difference, or price difference?
#1 price
for 2 strength, flex, bend breaking point, weight
(s class glass) is even too/better then carbon
(normal glass) is just slightly.. slightly weaker in most of those category's
by like 10%
so basicly look at it as cost effective
unless you want carbon looking parts no need
Carbon fiber is prohibited in Formula 1000 in any panel "licked by the airstream", so that includes the entire body plus radiator ducts. SCCA did that to keep costs down.
great job, touching things with resin on it with no gloves.
Hello I've watched a few of your videos now and like your process, for improving my own work why do you not use a roller when laminating? is this just your preference or is it something to do with a finsh?
+Ryan Abrahamson That's a good question, as I've used rollers with polyester resin when making the molds and body. The epoxy I can get is too thick to work well with a roller, so I'd need to use a plastic squeegee anyway after the roller. I can push much harder on the squeegee. Plus rollers are really hard to clean for repeated reuse.
Cool man that makes a lot of sense i will buy a squeegee with my next order and give it a try, thank you and look forward to more videos!!!
Some work went into those, what's the weight of the car all in?
I haven't weighed the car with all the body pieces on, but I expect it to be around 850 pounds. There's room to lighten it in the wheels, tires, floorpan and differential.
So clean
Respect!
how can i find the foam molds you have for the rear wing or did you cut them into that shape your self? great vid
this needs to be answered.
YOUR FACE he cut them himself. It says in the description
where did you learn all this?
That's a good question. Mostly I watched many TH-cam videos, then thought about it a LOT. This guy has a quick & dirty solution to most problems: th-cam.com/users/WJP004
Audio is crap. Why would you half-ass this.