Extra wide Carbon quarter panels without a mould. But was it worth it?

Carbon quarter panels using a foam technique. sounds easier than done! but is it worth the hassle?
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[@FirstLast-tx3yj]

remember when I suggested splitting the shell in half filling the gaps in the metal and doing it all in kevlar/ carbon then molding them together over the tube frame. You said it would be really expensive(which it would be it was just food for thought), but you are kinda inching your way to a composite shell

[@FirstLast-tx3yj]

listen... you are the fu**in man, doing everything from satrt to finish and I learned a lot from you. Keep it going and kevlar whatever you want!

[@RuskiWeldFab]

I appreciate that!

[@headsupracer]

Anotther great video Ilya! Very interesting the polyester coating did not attack the foam.

[@RuskiWeldFab]

Thank you

[@newagetemplar6100]

Just my opinion not a criticism but I always make molds . Far easier and takes no longer as theirs less finishing at the end with less chance of voids . Plus no door shut issues due to material thickness etc etc . If a panel gets damaged the Kevlar cannot be sanded then painted easily so it would mean making a new panel with nothing or little to go off . Price and labour to make a quick set of molds is relatively cheap . Anyone trying their own composite panels for the first time I recommend doing it in an environment where you can have some control over room temperature. Too cold and it can take days to cure to a decent state Too hot and the wrong speed hardener will lead to gelling half way through layup and either dry areas or voids . Weight saved higher up is more effective as it reduces the CG / roll center so any saving is a bonus as most will know . This should still be a quick car so let’s hope the engine issues etc are all sorted for next season and hopefully have some good runs mate . 👍

[@RuskiWeldFab]

A wealth of knowledge right here! Thank you

[@newagetemplar6100]

@@RuskiWeldFab no problem dude , like I said I’m not criticising anyone, trust me I know how hard it is and to attempt projects like yours and probably have a full time job and family it’s not easy . May cross paths next season if we’re out testing etc . 👍

[@tturi2]

love the content! especially the cooking show style of instruction

[@RuskiWeldFab]

Glad you like them!

[@barrysheldrick2704]

That looks brilliant, well done 👏🏻

[@RuskiWeldFab]

Cheers

[@lozogt3642]

Good morning, Sorry for the translation, I'm French with google translate... Thank you for all your sharing and the quality of your explanations! I also plan to make Kevlar pieces (wings/doors) and I have seen comments several times about UV exposure. What is your opinion on this subject ? Will it just change color from yellow to brown? Behind I will put either carbon or fiber (cost). Thank you for your feedback, I am impatiently awaiting your response.

[@oliverscorsim]

As a paint and body man we know 😂 iv had to do this a few times and although i do use similar methods i do a few things differently. For foam we use glued together foam thats precured its more stable. For making it the same we have a few tools but the best one is a skill. We learn to see with our hands. Iv gotten within the error range on pulling string.

[@RuskiWeldFab]

Right on

[@TnCountryBoy]

Awesome video. Thank you for the great instruction. Car looks great also. ! ! !😊

[@barrysheldrick2704]

3.6kg might not be as much of a saving as you hoped but it is also much wider than standard too.

[@RuskiWeldFab]

Exactly. At least I was not adding weight going much wider

[@thatmini]

Great job, love seeing the process you go through 😎

[@RuskiWeldFab]

Thank you!

[@x8dudtrackdaytoy]

Looks quality mate, good work

[@RuskiWeldFab]

Thanks 👍

[@radicalmuppets1600]

Love seeing how it was done! Was wondering how you would repeat the process if damaged (like if an Evo hits you)? And thank you for suggesting the Pocket 2! Have finally started putting it to good use

[@RuskiWeldFab]

Sure thing!

[@murphyspell7125]

I think if he uses the wide fender as a negative, he could make a mold of it to make new panels.

[@Carma.Repair]

Can also repair the damage just reskining if nessesary would add more weight but save a panel

[@AndyPonting]

Very good mate! Enjoyed that watch 👍

[@RuskiWeldFab]

Glad you enjoyed it

[@AndyPonting]

@@RuskiWeldFab I'd enjoy it a lot more if you came and did mine 😂

[@CarAndMechanical]

I think you hit the nail on the head with what you said around you would have gained weight with the widebody, so you have nicely flipped that weight for your end goal anyway, good work!

[@RuskiWeldFab]

Thanks

[@watersmart1]

Michelangelo would be proud of this piece of art.👍❤️🇨🇦

[@RuskiWeldFab]

Haha if you say so lol

[@watersmart1]

@@RuskiWeldFab No really, they can always use another teenage mutant ninja turtle!👍❤️🇨🇦

[@Carma.Repair]

Did mine similar way

[@RuskiWeldFab]

Yeah it’s not something new for sure.

[@BEYTEK]

Awsome job man im impressed

[@45BradB]

How do you manage the size difference between the original metal skin and the new composite piece? When you overlay composite on top of the original piece doesn’t it make the overall size bigger? Doesn’t it throw off the clearance of other parts like the door and roof?

[@RuskiWeldFab]

Yes correct. It does make part larger. But ask yourself this. By how much? And if that size difference is negligible or not

[@45BradB]

@@RuskiWeldFab so you don’t have trouble with clearance of the door? I was just wondering how it would turn out having done the front and rear wings if the door clearance wouldn’t be too tight or did you have to clearance the door? I’ve been following the build could but I didn’t see any mentions about this.

[@RuskiWeldFab]

i am sure i have mentioned it few times. size increase is negligible. part gets bigger by no more than 1-2mm. never had an issue

[@STU666V]

Well done 👍

[@RuskiWeldFab]

Thank you! Cheers!

[@DavidDewis]

Question, is having the rear panels curve around the back a good idea, compared to a squarer rear facing finish? Most performance cars (WRC, British touring cars, DTM etc) now have separation edges towards the back. Surely those wrap around curves are going to have some attached flow on them & create drag.

[@RuskiWeldFab]

Ahha! I am glad you mentioned it! Yes I am aware of the potential issues you are referring to. I am currently working on a solution to correct it 👍

[@DavidDewis]

@@RuskiWeldFab ah great to hear. Love to see what you come up with. You looking at modifying current panels or adding something to provide edges? I’ve considered 3D printing in flexible filament a small triangular channel that could be attached & moulded to older cars. Never actually got around to doing it though.

[@tturi2]

​@@RuskiWeldFabconsider a serrated edge like the Bonneville salt cars use, but at a 4° angle according to a study on aerodynamics of train cars and truck trailers (can't remember the name of the article)

[@Einimas]

The "newbie" plate tops it up :D

[@RuskiWeldFab]

yeah, been renamed since. its rather controversial!

[@BEYTEK]

not with easy composites no more?

[@ajwright5512]

To paraphrase eyebrow tutorials, don't ask me how I know, "Wide arches should be sisters, not twins".

[@kenecchi]

Do both sides and you'll have saved almost 10 kg; that's not at all insignificant. Plus the Kevlar panel is going to be much more durable, presuming it's at least a few mm thick.

[@RuskiWeldFab]

agree