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Unzipped Composites
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25.01.2022 Now everyone knows it's not about how big your wang is, it's how you use it; right Brandis Racing R32 Skyline??
25.01.2022 Whatever we're cooking up for the Brandis Racing R32 Skyline, it's high end! CNC'd patterns, pre-preg carbon skins, Nomex honeycomb cores, pre-preg adhesive films - all straight from the F1 Recipe Book of Advanced Composites!
24.01.2022 In other news, realised today it has been more than 4 years since we made this right-hand drive conversion dash for a 57 Chev! The build is still ongoing, but the car got a full respray a couple of weeks ago and a bit of overspray settled on the dash and dulled the finish. We dropped in with the Pai Crystal polishing system and had it looking as good as new in no time. Couldn't have the fancy new paint job out-shining our carbon work! Now it's time to take a look at building a mount for the Motec C1212 logger dash - whole lot of dash to fit in a tiny little space, but we'll work something out
23.01.2022 Hmmm, what could the Brandis Racing R32 Skyline be in for?
22.01.2022 What's going on here then?
22.01.2022 Another one: Custom ducted headlight replacement panel for AGD Auto Service Mechanical killer facelifted WRX. Passenger side has a straight replacement panel without the duct. Still need to fabricate brackets and finalise the fitment.
18.01.2022 Often custom work is more about imagination and the ability to 'see' what you are trying to create before you lift any tools. I believe most fabricators/pattern makers would agree that 98% of the battle is in conjuring the image in your head, and from there your hands just know what to do to turn it into reality. Sometimes it's easy and everything just clicks into gear. Other times, its a journey to the edge of madness that you only just make it back from. That was very much ...the case for producing this Motec C1212 dash surround. We started with a piece of wood cut to the exact size of the Motec dash, sat it in position, and stared at it for the rest of the day. Once that image finally formed, the physical shape was sorted in a couple of hours. And looking at it now, it could never have been anything different. Now the simple task of remaking it in carbon... See more
15.01.2022 While Maddog Customs were fitting the wing and oil cooler, Laine asked us to sort out some radiator and oil cooler ducting. Having previously had massive overheating issues, some radiator ducting was high on the priority list - as was maximising front downforce. We came up with a plan to try and get some airflow to the top of the radiator while also allowing Laine to block the top grill opening off again. With the passage of air between the bumper, intercooler and radiator ...now better sealed, and the air guide encouraging airflow to the top of the intercooler as well as diverting air from the license plate section up over the intercooler to the top of the radiator - hopefully Laine's overheating issues are behind him. While perhaps not quite as good as a fully moulded duct, this setup allows Laine to maintain the factory radiator position and support. The oil cooler ducting involved designing an inlet duct that could take air from the main front bumper opening in order to reduce the impact it has on the front aero, and directing that air via SCAT tubing to an outlet duct in front of the oil cooler mounted in the wheel well area. The challenge was packaging that duct into the area where the oil cooler is, as well as considering easy removal and fitting of the front wing/bumper.
15.01.2022 Apologies for the delay in posting up the results of the WRX roof, demoulded weeks ago but still waiting to be fitted to the car and we got carried away with other jobs in the meantime! I've had a few people asking me lately, so thought I'd better update! Untrimmed weight of the carbon roof is 2.9kg. Once we have cut the original roof off this customers car, we will weigh it all and post another update on how much weight we saved.
14.01.2022 EOI: These doors are available for sale. Brand new full carbon replacements, were only fitted to the car for one event before the car went into storage. Suitable for race vehicles only, as there are no provisions for windows or an intrusion bar. Weighing a complete 1.6kg each, you can not get lighter Lotus doors than these. If you or someone you know has a Lotus Exige being used for track work, please get in touch!
09.01.2022 When you realise you can make anything you like; why even buy cutlery anymore?
08.01.2022 Realised that we've been getting a lot of work done and not posting any photos of it! First up: Pre-preg carbon fibre flush mount for a Link ECU/Aim Technologies MXS Strada 1.2. Universal design retrofitted to a factory R34 GTR MFD surround. Apologies for the horrific photo quality of it fitted, the car is in a dark area of the workshop and it's very hard to get a decent photo.
07.01.2022 CNC spitting out a massive hint of what we are working on for the Brandis Racing R32 Skyline... lots to come.
05.01.2022 Well, it doesn't always go to plan. After putting in a 23 hour shift yesterday to get the Lotus door moulds polished, prepped, laid up and infused in order to get these doors finished by tomorrow, we've come back several hours later to find one of the outer skins developed a leak post-infusion, which will virtually guarantee it is destined for the bin. Maintaining an ultimate vacuum of 1 millibar is crucial to the success of an infused panel, and we use top of the range ultr...asonic leak detectors, high precision digital vacuum gauges and perform a minimum 8 hour leak down test in order to have the highest possible success ratio. Unfortunately sometimes things find a way past all the precautions, and thats just the nature of the game. Will leave these now to fully cure until tomorrow, then demould and use these laminates as another lesson in the school book - then do it all again!
05.01.2022 Lotus doors done. Weighed in at 1.6kg each side, not including the latch mechanisms or hinge. The factory fibreglass skins (so also not including the latch mechanisms, hinges, window mechanisms, or the reo bar) weighed in at 15.1kg each side, so we've saved 27kg in just the door skins. The window mechanisms and reo bar have also been ditched, so the weight savings are even higher. Strategical fibre alignment and localised reinforcement in conjunction with the clever original double curvature design means that the doors are still very stiff despite their weight, meaning the doors don't flop around or feel cheap when they are unlatched.
04.01.2022 This post has been a long time coming. After months of development, with over 2000 hours of work put into it, we are very excited and proud to have sent the Brandis Racing R32 Skyline home yesterday sporting our brand new twin element front wing package. This package is an optional upgrade for our modular front splitter, meaning that these wings are made entirely to suit your car without the massive costs of developing a custom one-off setup. Designed in-house using OpenFOAM... 2D CFD simulation, we started with a well known and proven ground-effect NACA airfoil profile and modified its camber in order to achieve a static pressure distribution that maximises downforce whilst minimising the downstream impact this has on the rest of the car. The wing itself is constructed entirely from pre-preg carbon fibre as a hollow body with a structural main spar bearing most of the load, and strategically placed aluminium honeycomb for maximum rigidity at minimum weight - the entire thing, at over 2000mm's wide and 800mm's deep, weighed in at 9.3kg. In Laine's case, we also structurally bonded the TopStage airdam to the wing, while Maddog Customs are responsible for the brilliant mounting solution. The OEM front bumper is mounted to the wing via Chromoly tubing, which also slot into receivers on the chassis that enable the entire setup to sit in position hands-free before it is secured with just 2 bolts, making it very quick to install and remove.
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