Building a Rear Wing with Carbon Fibre and Nomex

Product links ► www.easycomposites.co.uk/lear...
Further information and links ▼
In this step-by-step video tutorial we demonstrate a method of making high performance carbon fibre downforce/aero wings for motorsport without needing a mould. Instead, carbon fibre is laminated onto the outside of an XPS foam core which has been profiled using a hotwire cutter. Mylar is used to smooth the carbon fibre and a vacuum bag is used for consolidation. End plates, which include aluminium mounting inserts, are made using Nomex honeycomb bonded to carbon fibre sheet.
00:00 - Introduction
01:37 - Hotwire cutting XPS foam core
04:05 - Machining wing inserts
05:21 - Cutting Mylar surface film
06:14 - Prepare the vacuum bag
06:31 - Preparing the carbon reinforcement
07:33 - Wet-out reinforcement with epoxy
09:18 - Wrapping the carbon fibre around the foam core
11:22 - Machining the carbon sheet for the end plates
13:06 - Aluminium inserts for the end plates
14:56 - Cutting and bonding Nomex honeycomb
18:09 - Filling the edge of the honeycomb panel
18:36 - Assembling the finished wing
For further information, including links to all products used in the tutorial, see the tutorial's project page on the Easy Composites website:
Full Project Details
UK and World ► www.easycomposites.co.uk/lear...
EU ►www.easycomposites.eu/learnin...

[@kingsed91]

Guys, I dont know if you understand the impact of this video. You have basically revealed the secret of how to make decent wings for all formula student teams. As somebody who has been developing the method for my team, this is both blessing and a curse. Through hours of research I have basically settled on a process almost just like this. And now the effort seems pointless. I have also figured out mylar is the magic ingredient, but I could not find a supplier who would be selling it by metre in the full width. And BOOM! Easycomposites now sell it, in the same spec as I have seen elsewhere, only they also let you buy per metre. Another thing are the endplates... again, basically the same process. I love you, and I hate you at the same time 😂

[@easycompositestv]

Haha 😂. Well, you’re welcome and I’m very sorry, all at the same time! Good luck to your team and we’ll done for your hard work!

[@BenjaminKing1]

@@easycompositestv yeah, this would have been amazingly helpful when I did Formula SAE back in the day!

[@7null]

I own a old fsae car with humiliating bad layups. Still works but sad downforce. Thanks for this step by step... Impressive quality. What would cost be for all the raw goods you used here?

[@easycompositestv]

@7null for the materials, excluding the equipment (vacuum pump, saw etc.) you'd be looking at about £250/$300. It's hard to say exactly because if you make just one then you'll have offcuts that you don't use (like the Nomex, you won't need much of) but it would be in this range.

[@7null]

@@easycompositestv Thank you. This really helps put in perspective and how attainable this technology is compared to 24 years ago we built this fsae car.

[@navigas93]

The effort, time and dedication you put into these videos have made my BSc thesis into an A+, it makes me want to improve almost everything around me and it have made you a lifelong customer and me as an (free of charge) ambassador for my fellow interested DIY'ers. Thank you Easy Composites - and especially you Paul.

[@easycompositestv]

Thanks so much for the feedback Mathias, that’s great to hear and we really appreciate your support!

[@jimj2683]

@@easycompositestv When will you offer graphene enhanced prepreg carbon fiber?

[@anthony3064]

This youtube channel is a legend for teaching every carguys dream parts, ShoutOut from the Philippines 🇵🇭

[@easycompositestv]

Thanks Anthony, appreciate the support 😃.

[@OfficiallySnek]

Definitely make the video on molded wings! The information you provide is extremely useful to many people out there

[@easycompositestv]

It is one we are planning.

[@OfficiallySnek]

@@easycompositestv Looking forward to it :)

[@PerWiklund234]

@@easycompositestv Awesome. I have been struggling with that for a long time trying to make precision hydrofoils. I can't wait

[@ChuckThree]

Almost every single video y’all have done for last 2-3 years has been immediately relevant for me. Like, almost concerningly so lol. Not sure how you know exactly what my next subject matter needs are, but keep at it 😂👍 Thank you Paul and the Easy Comps team!

[@easycompositestv]

Haha, we’re not giving our secrets away but we’re interested to see what your next project is so we know what our next video is!

[@ChuckThree]

@@easycompositestv if either “Make a Full Width Carbon Fiber Dashboard” or “Easy Carbon Body Panels with Wet Layup Over Sheet Metal” pops up in my feed in the next 6 months, my suspicions will be all but confirmed.

[@MeatPez]

I cannot believe you give years worth of research and work for free in an easily digestible video. As someone who knows how difficult it can be to teach yourself a very in depth skill with little public info, I applaud you for this.

[@tommylongman25]

This is almost identical in every way to how we've made wings in formula student. Very cool to see that the method is something easycomposites think is good enough to share as well! I'm super impressed with how nicely yours came out. If only ours were as nice every time 😂

[@easycompositestv]

Thanks Tommy, I guess we’ve had a fair bit of practice! And yes, it’s an ideal method for FS requirements.

[@easycompositestv]

Thanks Tommy, I guess we’ve had a fair bit of practice! And yes, it’s an ideal method for FS requirements.

[@SONO4B11T]

The university I hope to be in next year doesn't have a FS program. So I hope I can master up enough support to get it going, and this video is a perfect motivator!

[@vincegarage1293]

back in 2012 when i thought about making a mould of motorcycle bodyparts, i watch him in the other channel. 11 years later to 2023, when i think about making carbon parts, i still watch him. hahhaha think you are dracula man, no aging at all. your 13++ years of experience make it look so easy to handle all those sticky & itchy things. awesome

[@mrrustygray]

I feel like I am in composite college when I 2watch these vids, over and over. So much knowledge. Thank you.

[@elminz]

Subbed to several hundred channels, yet Easy Composites' tutorials are consistently in the best on any topic. I like the fact that you concisely weigh up pros/cons for alternatives, as well as giving an accurate representation of good real world results, i.e. not perfect, but pretty damn good considering.

[@easycompositestv]

Glad you find them useful and enjoy watching them.

[@antoniofranklyn5923]

I enjoy watching content from easy composites. They give me the motivation to do the projects i want to do. Thank you easy composites for making this content and introducing the rest of the world to this skill!

[@easycompositestv]

You’re welcome Antonio, thanks for watching; it’s great to think we’re inspiring people to give things a go. That’s what life’s all about 😀.

[@EG4Honda]

"production quality finish" Mate, I think commercial producers of composite parts couldn't even dream of achieving an "Easy Composites quality finish". Your knowledge AND technical skills are incredible.

[@easycompositestv]

Haha, that’s very kind. Production quality *should* be at least this good, but.. agreed… it isn’t always!

[@rodrigopena4602]

Since I joined my Formula Student team, here at Brazil, I've been following Easy Composites channel. I really appreciate the effort you put in to tell us all of this information for free. I wish we could have all the materials and tools you show in the video but we try to achieve the best with what we have. Thank you very much for these informations, especially since I work in the aerodynamics area and we aspire to build a new aerodynamic package for our project.

[@easycompositestv]

Hi Rodrigo, thanks for you message. It’s great we can share this information with you even if we’re unable to supply you. I wish you your team every success.

[@colewilson2]

Just dropping a comment to let you know how much I appreciate these videos. I'm gathering the confidence for a carbon fibre project, and the way the information is presented and explained in all of the Easy Composites videos is just simply incredible. Dispite likely paying for higher shipping costs, my money will absolutely be spent here for anything that is available to get shipped to the US. Thank you!

[@easycompositestv]

Thanks Cole, we really appreciate the kind comment. If you do decide to undertake a project we'd be more than happy to provide technical advice by email which may not necessarily be covered in our videos!

[@MakingforMotorsport]

Paul’s back! Wing elements you say? Downforce indeed?? Right then, just let me get comfortable… 🍿🍿🍿

[@easycompositestv]

Haha, hope you enjoy. We’re avid followers of your channel too 😀.

[@MakingforMotorsport]

@@easycompositestv cheers bud… can’t wait until I can unleash some of this CarbonFibre goodness and EasyComposites skills on the Mini… 👍

[@CYMotorsport]

EDIT: 6:50 i've been using different weaves in different applications across many use cases for years. for some reason, i've never even thought to try this. wow. Need to make this replica for my sim rig! brilliant, as per

[@easycompositestv]

That would certainly add to the authentic look of the rig!!

[@EndroEndro]

it is a add of products/page but it's well done, not annoying and that man is on top level if we say clear, proper explaining.

[@jinxtacy]

Amazing. You even go into the topic of galvanic corrosion which distracted me through the first bit of the video seeing aluminum in contact with carbon. I had always assumed that stainless steel or preferably titanium were the options. Oddly, I generally like the parts that are created and that drives my interest, but your presentation really makes the process enjoyable rather than just the end product. Thanks for the content.

[@SoumilSahu]

Really wish we had this video when I was in Formula Student. This is an invaluable asset to the motorsports community. I can definitely empathise with the frustration of people who figured all this out themselves, but hey, more competition is always fun!

[@stevesloan6775]

Your videos are absolutely top shelf. Its hard to imagine just how many projects have been started, purely thanks to your amazing tutorial videos. Much love from Australia.

[@andypuempel2570]

I always look forward to the EasyComposite content. Very well produced video and very educational. Thanks for your efforts!

[@easycompositestv]

Cheers Andy. Positive comments keep us motivated to produce this content 😀. Well, that and we love doing it!

[@MrYoyojuan]

I have been thinking of making some nomex/carbon fibre panels for DML speakers, so you confirmed how I was thinking of doing it but added the little details like thickening the epoxy and edge finishing for me. Great stuff, I really appreciate the effort you guys put in to make your videos informative but not intimidating for us DIYers with little experience.

[@seandeterman2499]

You guys really don't understand how much we all appreciate these videos! So cool and I can't wait to try some of the projects on your channel! Thanks!

[@easycompositestv]

Thanks Sean, we appreciate your feedback. Good luck with your projects.

[@flaviovianna4889]

THE BEST composites content on KZbin. Big Fan! Not a big client yet due to limitations with shipping to NZ, but soon I will be closer.

[@easycompositestv]

Hi Flavio, thanks for the support. If your comment means you're moving country then we wish you all the best with that and look forward to being able to supply you more easily.

[@bbrown9763]

Your videos are truly exceptional. Chock-full of useful tips through the entire process. Well done, everyone!!

[@easycompositestv]

Thanks a lot 😀.

[@parthghube02]

One of the best channels on KZbin!! Thank you Easy Composites

[@UWcharlie1983]

A huge thank you to Paul and the entire Easy Composites team for all the effort you put into creating this content. I would be extremely interested in watching a video on the details of how aero wings are made using molds.

[@easycompositestv]

Hi Charles, you're welcome. Vote noted; there's been lots of interest in the moulded version of wing production so this is certainly something we'll think about.

[@wellreally831]

loving all the small tips and tricks :-D very specific instructions and also mentioning where no big effort is needed (glue of the end plates)

[@easycompositestv]

Thanks, appreciate it. And yes, it’s good to point out where too much effort isn’t needed, that way you can focus on when it is!

[@oghomelesskid]

Paul, youre an absolute legend! thank you for all these videos!

[@easycompositestv]

Glad you like them!

[@user-oj4xh8cg2l]

Brilliant ! you make such a technical part almost (...) easy to fabricate...

[@carlnewtonfishing6045]

What a great video again. I really wish you could make them more often. Never have any intention of making that wing, but really enjoy the process you go through. I watched every minute of it with great interest.

[@easycompositestv]

Thanks Carl. I totally get this, I’ll watch videos of processes that I’ll never follow either but it always feels worthwhile to learn at least a little bit about how different things are made 😀.

[@efaracing4000]

On the behalf of the people who haven't great video and info as always thankyou!

[@JaviRP97]

Brilliant video. I've been following Easy Composites for quite a while and I always end up amazed by how well explained every step is. Learning a lot. This one is particularly useful for me since I'm going to start making foam cutting and composites tests today. Thanks a lot for all the effort. Cheers!

[@easycompositestv]

It's our pleasure, glad you're enjoying the content.

[@dhupee]

i never played with carbon fiber(maybe will), but my fellow FS guys do and you guys are big part of their knowledge, even though we are not customer yet, but still thank you so much for providing this amazing knowledge

[@easycompositestv]

Thanks Daffa, we’re all about sharing the knowledge, whether viewers are customers or not, we appreciate the feedback 👍.

[@g-ten5879]

Great job! thanks for Teaching us How to make them perfectly practical and clean

[@maikolnay]

just watching your videos gives me the courage to continue practicing!! 💯

[@Kyrazlan]

Molded wings? YES PLEASE!

[@georgef1176]

That came out so great! Very simple.

[@miguelm269]

Very nice as always!! Yes please, video using molds would be great! Thanks!

[@easycompositestv]

Hi Miguel, vote noted. Lots of interest in this video so I think it will happen : )

[@capnthepeafarmer]

Great job on another wonderful tutorial! You are the go to resource for composite tutorials and supplies, keep up the great work!

[@easycompositestv]

Really appreciate the kind comment!

[@WeAreChecking]

Absolutely class act, as always gents. Thanks for putting these out!

[@easycompositestv]

You’re very welcome Richard, thanks for watching.

[@thesighbored]

Awesome job, thanks for sharing the process!

[@teodortibblin9092]

Very nice result!! Great work.

[@JohnChuprun]

Awesome video. Masterclass type material here! Thanks Easy Composites

[@malcolmstoddart8967]

As normal - excellent presentation, no BS, everything explained perfectly, and I am looking forward to the next video already!

[@easycompositestv]

Next video is us blowing this wing up! We’ve filmed it but need to edit it down 👍.

[@pezomatic1]

I literally have spent the last 12 months on and off moulding. Prepping and making my own carbon wing from scratch. I wish I knew this method existed 🥲

[@martinnovation1]

excellent video. What a playgorund you're in there. All the best tools and materials within hand's reach

[@easycompositestv]

It is our dedicated testing and training facility so set up specifically for the task.

[@bernardmcnamara]

Thank you. What a excellent demonstration. From 🇦🇺

[@easycompositestv]

Thanks for commenting Bernard! Glad you enjoyed!

[@RenegadeADV]

Loved this video man, I have wondered how to make these for years.

[@spencerwvcmoon]

Wonderfully really enjoying my projects! Thanks easy composites you are a godsend to me.

[@easycompositestv]

Cheers Spencer, you're very welcome, glad you're enjoying your projects.

[@Ther2000]

Great one! I would really love an in depth video on core materials, their ups and downs and how to process them.

[@easycompositestv]

Great suggestion!

[@leebullen2010]

Hi Paul, just watched the wing build and test videos.... as always fantastic videos. Keep up the great work 👍 Lee Bullen.

[@slimanus8m]

Great video as always, I enjoyed it, thank you

[@liamgleason3416]

I would love to see a few more parts about different moulded methods using vac bags and pre preg

[@OutsideCleaners]

Thank you so much for sharing this info... a process for those of us at the lower-end of the fancy-scale.

[@reggieeng51]

This is a video I have been waiting for! Definitely interested in the molded wing process, esp. in the context of wings/winglets in MotoGP or for RC usage

[@easycompositestv]

Thanks for the feedback Reggie; looks like there’s lots of interest for the moulded version so this is certainly something we’ll start thinking about.

[@rolfnilsen6385]

They mylar trick, and the "filleting" for the nomex was all new to me. Great stuff!

[@easycompositestv]

Glad you found it useful.

[@Chris71920]

I work with pre-preg every day within a team, but your videos are always of interest 👌 Keep up the good work!

[@easycompositestv]

Cheers Chris, glad you’re enjoying seeing other processes and materials. We can all learn something from others, and you could probably show us a few tips as well!

[@sacrificialrubber779]

An absolute beauty of a wing!!

[@maxsam201]

So enjoyable to watch, every time.

[@itz_lexiii_]

Thank you very much for making a tutorial like this. Even if I may not be using this tutorial for years to come it is still very valuable information

[@easycompositestv]

You're welcome, it's always good to understand how things are made (or what processes for making exist), even if it's just to broaden your general technical knowledge.

[@kirtleybellotti9603]

One of the best channels on youtube

[@andwjy]

Made the wings, the body, later on the engines etc. and in the future video: Team Easy Composite dominates the race 😉

[@mrpotatoheadie]

Top quality content as usual, the effort is very much appreciated by educators like me. It makes it easier to support students exploring hands-on projects, so thank you.

[@easycompositestv]

Thanks for the feedback Keith, we get a lot of support from educators who use our content to support their teaching and it’s great to hear.

[@mrpotatoheadie]

@@easycompositestv I get the impression that you all enjoy and take pride in making the quality of videos for current and future customers, long may that continue... I'm also very jealous of your workshop/studio 🤣

[@andreasnotzon7270]

thanks for the many good suggestions. your videos are always very instructive, entertaining, inspiring and personable. please more racing car stuff! 😊

[@easycompositestv]

Thanks Andreas. We’re racing at our core so we always plan to do more motorsports based projects!

[@Boogie3D]

Perfect way to show the process, thank for that as usual. One thing that should be taken care of is making sure that the wing is not twisted/doesn't have any dihedral. In RC model airplanes, when vacuum bagging a wing, we place it in the foam cores and put some weight on the top to make sure that neither of the things mentioned happen.

[@easycompositestv]

Thanks and good advice. Any twist or bend would of course be much more significant on a plane than a car where the wing is just a small contribution towards the dynamics of the vehicle, but good advice for sure.

[@wallymcguire2033]

Incredible quality, both in the result of your product but in the creation of your content. Excellent work. 👍

[@easycompositestv]

Thanks Wally!

[@blakechesbro3602]

These are amazing tutorials, Just cannot imagine a DIY'er to have all this sophisicated tooling for my home racing operation. Still valuable all the same, really enjoying these.

[@easycompositestv]

All the CNC work shown in this video can be done by hand with a variety of hand and power tools so it is not necessary to have a lot of sophisticated equipment.

[@blakechesbro3602]

@@easycompositestv thank you

[@ronweasley4628]

Fabulous as usual - us poor penniless club racers need all the help we can get 🙂 Show us how to modify this process for centre supported wings - lets do some small front wing elements, and show us every which-way it can be done 🙂 Thank you very much.

[@easycompositestv]

I'm really glad that you enjoyed the video and we appreciate you taking the time to comment! Hopefully the upcoming videos are as useful!

[@mattapple2105]

This is really a spotless and perfect presentation on how to do it, very well done Mate : )

[@easycompositestv]

Thanks a lot, that's really appreciated, maybe perfect is a stretch but I'll take it!

[@bobsnabby2298]

Best tutorial on Internet!

[@gabrielpinananaharro7154]

Consistently the best tutorials about anything. Cheers!

[@easycompositestv]

Really appreciate the kind comment!

[@starby1243]

Amazing work. Wish I could do these things

[@jumiduss]

Awesome video as always. Appreciate these videos so much and look forward to making some projects soon with your products. Y'all are great!

[@easycompositestv]

Appreciate it, thanks.

[@billyvray]

Please do a video on your Hotwire cutter!

[@macbouncer8525]

another excellent instructional video... many thanks.

[@Alejandro-vg7yt]

Use TeXtreme spread tow fabrics as they are already stabilized from the box 😉 Excellent video, cheers!

[@mihai66hrc]

Very good content, I really appreciate the effort you put into this. Maybe next time you can insist on how to finish the cut part to look flawless. Thanks!

[@tinolino58]

The Mylar is the key! Great video! Thanks 🌸

[@easycompositestv]

Yes the stiffness of the Mylar film makes a big difference to the surface finish.

[@jonhimself77]

Absolutely superb video.

[@sergiotondini5914]

Bravissimo complimenti bellissimo il servizio molto chiaro 👍👍👍👍

[@onepairofhands]

Awesome presentation as usual - great result too

[@easycompositestv]

Glad you enjoyed Peter! Thank you for watching and taking the time to comment :)

[@MechatronCNC-HVM]

Another great tutorial 😎👍 thanks for sharing.

[@easycompositestv]

Thanks for watching and commenting! Glad you enjoyed :D

[@davidgruty]

You've done it again Paul, amazing!

[@easycompositestv]

Thanks David!

[@rkstewart9585]

Outstanding video as usual.

[@user-bd6go6pf4f]

Чудова робота та прекрасний відео посібник! Дякую!)

[@alexandrefernandes6286]

Great content. Awesome, very detailed. Thanks for this.

[@easycompositestv]

Appreciate the really kind feedback!

[@VasilisKavanozis]

I was waiting this video!! Thanks!! 👏🙏

[@SilverStackers]

AMAINZING WORK

[@runcycleskixc]

These guys a great, been buying epoxy and fiber from them for years. My products are nowhere near as perfect, but the amount I learned about resin helped in my science research (nanotech).

[@easycompositestv]

Thanks for the feedback - it genuinely makes us want to do more! :)

[@alexandrealaniz]

Amazing. Fantástic vídeo!

[@millerchassis6119]

best carbon videos online by far, awesome video as always. would love to see you guys do the video on the molded version you spoke about at the start of the video thanks again

[@easycompositestv]

It is a future video we hope to do.

[@millerchassis6119]

@@easycompositestv sounds fantastic thanks.

[@__dm__]

thank you british composites man, very cool! jokes aside, I love these videos; it's really nicely made and easy to follow. I've played with your forged process and it was a lot of fun.

[@easycompositestv]

Thanks DM, that’s nice to hear. Glad you enjoyed experimenting with the forged process too.

[@Firebird356]

Absolutely fantastic! Thank you.

[@easycompositestv]

Thanks Roger!

[@pedrorocha870]

Already eager to watch the test of the wing! Great content

[@easycompositestv]

It won't be too long before it's uploaded :D

[@projectx-22racing85]

Excellent Videos! Thank you for the information

[@easycompositestv]

Thanks, you’re welcome 😀.

[@mohammadaldahoudi]

You guys are amazing 😊

[@caleb8754]

Loved this content. Would love to see the molded manufacturing of a airfoil

[@easycompositestv]

Thanks Caleb, upvote noted! We’d like to make the moulded version too so stay subbed and hopefully we’ll get on it soon.

[@210Artemka]

Here is the video of a guy using similar technologies (without any CNC tools) to build a mold for a wing for his DIY sports car: kzbin.info/www/bejne/jJK6Z3WPmbmol5o. A lot of working with composites on his channel, I would highly recommend watching it.

[@mrrexy4151]

I was enjoying every second of video!

[@easycompositestv]

Haha, thanks, glad you enjoyed it!