Cosworth YB Turbo Into Elan

Post by: **msd1107** » Mon Sep 14, 2015 3:41 pm

Oooh, first step to a carbon fibre replacement shell! Let us do it!

I row Olympic class shells, and my pair (for two rowers) is 10 meters long and less than 27 kg. Very impressive.

David
1968 36/7988

Post by: **el-saturn** » Mon Sep 14, 2015 3:55 pm

.......................................yikes once again, pretty rough carbon laminate and why the ..... does a car like this need (nice job though) need a handbrake???????????????? i know, ask a silly question, get a silly answer! sandy --- 36 / 4982

Post by: **stevebroad** » Mon Sep 14, 2015 5:18 pm

el-saturn wrote:.......................................yikes once again, pretty rough carbon laminate and why the ..... does a car like this need (nice job though) need a handbrake???????????????? i know, ask a silly question, get a silly answer! sandy --- 36 / 4982

No flow coat yet, hence the rough look :-)

It will be smooth when finished. Bear in mind that I was using the original roof as the mould to save having to make a mould, so what you are seeing would normally be the inside surface of the laminate. The underside of the roof is smooth and shiny :-)

Handbrake required for MOT as it will be road legal.

Post by: **stevebroad** » Mon Sep 14, 2015 5:23 pm

msd1107 wrote:Oooh, first step to a carbon fibre replacement shell! Let us do it!

I row Olympic class shells, and my pair (for two rowers) is 10 meters long and less than 27 kg. Very impressive.

David
1968 36/7988

I have a lot of carbon as we were going to make a CF body. Circumstances have now precluded that option so I have to do something with it :-)

If I decide at a later date to make removable front and rear sections they will be in carbon, obviously :-)

Post by: **elan66** » Mon Sep 14, 2015 6:41 pm

Hi Steve looking good,how does the cost of carbon compare to glass,and do you still lay it up the same,
regards
Paul

Post by: **stevebroad** » Mon Sep 14, 2015 9:12 pm

elan66 wrote:Hi Steve looking good,how does the cost of carbon compare to glass,and do you still lay it up the same,
regards
Paul

Compared to carbon fibre, fibreglass is free! :-)

CF is around 10 times the price of woven glass fabric and 20 times that of chopped strand mat.

The laying up process is basically the same, just different material and resin. CF is less flexible than fibreglass chopped mat, more like woven glass mat, but there are various weights and weaves so there is no direct comparison.

The trick is to use as little resin as possible - less resin=more strength and less weight. I aim for the same weight of resin as CF.

Post by: **holywood3645** » Tue Sep 15, 2015 4:49 pm

Different topic...Steve do you have the elan adjustable camber top control arm for sale?

James

Post by: **stevebroad** » Tue Sep 15, 2015 8:20 pm

holywood3645 wrote:Different topic...Steve do you have the elan adjustable camber top control arm for sale?

James

Hi James

Not at the moment. They needed an insitu design change in order to clear the damper spring seat and I haven't updated the CNC drawings/program yet. Are you in a hurry?

Steve

Post by: **holywood3645** » Tue Sep 15, 2015 8:26 pm

I liked your design the best. Running positive and need to fix. Please PM me price and availability
Thanks
James

Post by: **stevebroad** » Thu Sep 17, 2015 1:21 pm

First fit of passenger door (UK). A bit of fettling seems tobe required in order to make the gaps a little bit smaller :-)

Post by: **el-saturn** » Thu Sep 17, 2015 2:06 pm

...........RESIN content is 15% as far as i remember: hardly attainable if handlaminated!! cheers PS: epoxy resins are much more toxic than polyester!! --- prepregs even more so!! sandy

Post by: **stevebroad** » Thu Sep 17, 2015 5:02 pm

el-saturn wrote:...........RESIN content is 15% as far as i remember: hardly attainable if handlaminated!! cheers PS: epoxy resins are much more toxic than polyester!! --- prepregs even more so!! sandy

50% is hard to achieve by hand!

Plenty of ventilation ;-)

Post by: **el-saturn** » Thu Sep 17, 2015 6:14 pm

how far do u get if you squeeze the resin out AND vacuumize the component in a well prepared bag?? sandy

Post by: **stevebroad** » Thu Sep 17, 2015 9:48 pm

I have no idea, as I have yet to progress to bagging. I have the vacuum pump so I just need the consumables and inclination :-)

I have yet to make the tunnel cover so I may try bagging that.

Post by: **stevebroad** » Sun Sep 27, 2015 8:30 pm

Removing the door skin and replacing it with a carbon fibre one allowed me to adjust the door frame so that it fits the hole and doesn't stick out at the bottom. The carbon fibre skin is now a little short around the edges but that can be dealt with.

By drilling over 400 holes I managed, along with the CF skin, to halve the door weight from 6.1kg to below 3kg.

I have had to replace the lock support plate that is attached to the window frame, so I have made a carbon fibre one.

Cosworth YB Turbo Into Elan

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