Yeah, when we did 2 layers we set them up 0 and 90 degrees rotated. When we did 3 layers it was 0, 45, 90. But for some stuff that had the potential of taking hits (like the bottom of our side pods) we used fiberglass since we didn't want to scrape off the expensive carbon fiber. But we layed up a frame work of balsa wood to, how I can best describe like a grapefruit would look. The area where the "fruit" is was then filled with a honeycomb matrix. Then we sandwiched it between a single layer of fiberglass on each side. The damn things were strong as hell. We actually gave good attempts and breaking them by hand (slamming over knees and banging on corners of tables) and they wouldn't.

But to get the true aerospace stuff, they get super crazy on their dry layups and prep work. Then they pressure bake them on top of the vacuum sealing (or maybe it's the pressure cooking that they don't need to vacuum. We could have maybe done similar work, but we decided to not build structural components when we could just machine the stuff out of blocks of aluminum.

But stuff like body panels, or interior panels (think custom dashboard) if you got a big enough oven, vacuum pump, and time you could probably make some light weight parts yourself pretty easy.

Yeah, at Danner, the parts are usually bagged, then autoclaved. Was your honeycomb a paper type? Or something else? I know the stuff they use on the aerospace stuff is just a paper like substance.

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Welcome to the cult of JVL drink the koolaid or be banned.

We used aluminum honeycomb for our front crush zone. The rest was paper type.

Man all this composites talk makes me want to build a fiberglass dash for the Honda...

Interesting. Thanks for the info!

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Welcome to the cult of JVL drink the koolaid or be banned.

BillyElliot Wrote:
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> We used aluminum honeycomb for our front crush
> zone. The rest was paper type.
>
> Man all this composites talk makes me want to
> build a fiberglass dash for the Honda...

Oh yeah the differnce between 24th and 1st OVERALL will be found in that dash, mang!
DOOOOO EEEEEET!

Do the door panels in CF and people will just give up before they unlaod the car off the trailer!

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John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.

I didn't say I wanted to do it to go faster. I just get a kick out of doing stuff like this because the last time I did composites lay up was a several years ago.

Granted I would need to build a ghetto stove to cook a dash in to do the project. Hell, could even save steps by using the dash as the mold.

/sigh

If you want to do some carbon work, why not build something useful.
Like FIA side impact carbon/honeycomb panels.

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Grant Hughes

Hey, you wrap your sandwiches in aluminum foil? Airplanes are made of aluminum! Why don't you make yourself useful and build us a 747?

-D

eyesoreracing Wrote:
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> Hey, you wrap your sandwiches in aluminum foil?
> Airplanes are made of aluminum! Why don't you make
> yourself useful and build us a 747?
>
> -D

How about an aluminum /pastrami/provalone/lettuce composite glove box door?
It would be so unique!!!

---

John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.