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May 31, 2020 20:30:36 GMT
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Made the access panels for the doors today. I give them 7/10 as there were a few miscalculations and I should have radiused the corners rather than simply cutting straight lines. Oh, well, once tidied up and painted they won't be too obvious and I can get to the locks :-) Made the captive nuts (14, only 12 in photo as I changed the design slightly during layout) and they are quite a bit lighter than the ones I bought for the screens - overall a saving of 49gms. If you want a car to be lighter the devil is in the detail :-) However, I will be using the steel ones for the screens despite the weight penalty, which will actually be less as I would have them more substantial, as they have a bigger job to do than just secure an access panel. Comparison between shop and home nuts. They will need to be trimmed, as can be seen in the photo, so as to not extend past the screen support.
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Last Edit: Jun 1, 2020 8:27:52 GMT by nalesutol
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Had a final session of grinding on the passenger door, prior to sticking on the inner panel, and added 100gms of lightness :-)
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OK, passenger door finished apart from prep and paint. Original Elan door, all up, weighs 16kg with the bare carcass being 6kg of that. I managed to reduce the carcass to 3.2Kg by drilling 400 holes and replacing the front skin with un-vacuumed wet lay carbon. I have moved on with my CF skills since then so decided to re-visit the door. I removed the CF skin and made a new one using prepreg carbon. The original CF skin weighed more than my CF driver's door carcass! New door weighs in at 3.6kg, including hinges, lock and polycarbonate glass. It will be interesting to see how much the fully carbon door weighs in comparison. I reckon around 1.5kg less.
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Last Edit: Jun 2, 2020 14:04:00 GMT by nalesutol
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bstardchild
Club Retro Rides Member
Posts: 14,937
Club RR Member Number: 71
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OK, passenger door finished apart from prep and paint. Original Elan door, all up, weighs 16kg with the bare carcass being 6kg of that. I managed to reduce the carcass to 3.2Kg by drilling 400 holes and replacing the front skin with un-vacuumed wet lay carbon. I don't know what impresses me more - The fact that A. You drilled 400 holes in a door or B. You counted them Nope still can't make my mind up............
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OK, passenger door finished apart from prep and paint. Original Elan door, all up, weighs 16kg with the bare carcass being 6kg of that. I managed to reduce the carcass to 3.2Kg by drilling 400 holes and replacing the front skin with un-vacuumed wet lay carbon. I don't know what impresses me more - The fact that A. You drilled 400 holes in a door or B. You counted them Nope still can't make my mind up............ :-) Well, after I had finished I thought 'that is a lot of holes. I wonder how many?' So I just had to count them :-) Now I know how many holes it takes to fill an Elan door :-)
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Passenger door finally complete and surprisingly stiff now the inner skin is glued on. Now begins the task of making it presentable and ready for paint. Started work on the driver's door. This has its challenges as I had to raise the bottom corner of the windscreen due to it being low. I discovered this when I was setting the car up in readiness for the roll cage to me made. I got the chassis level and found that the top of the screen was low. I cut the A pillar in order to level it up but this then required the bottom edge of the screen to be adjusted to match. This resulted in a lift of around 25mm. All looks good but a knock on effect was that the door was now too low. I used the existing door as a pattern for the mould but I have now got to make it fit. The car body was a mess with nothing lining up but is should look OK if you don't look too closely :-) The window support in the top of the door comprises of 4 parts and I was able to line this up with the new body line. However, as shown in the second photo, the outer skin is a little short so some extra work will be required to sort this out.
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Last Edit: Jun 3, 2020 23:33:10 GMT by nalesutol
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Filleted? I meant fettled. Also, 2.6kg is 5.7lbs. I put it down to stage fright and no script :-)
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joeytalent
Part of things
ITB Everything.
Posts: 440
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Filleted? I meant fettled. Also, 2.6kg is 5.7lbs. I put it down to stage fright and no script :-) Appears to be private at the moment
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Filleted? I meant fettled. Also, 2.6kg is 5.7lbs. I put it down to stage fright and no script :-) Appears to be private at the moment Hopefully sorted.
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bstardchild
Club Retro Rides Member
Posts: 14,937
Club RR Member Number: 71
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It is indeed
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biturbo228
Posted a lot
Posts: 1,848
Member is Online
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The attention to detail on this still completely blows my mind!
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What is the gray that I see on the panels?
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What is the gray that I see on the panels? Primer.
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Jun 10, 2020 11:09:12 GMT
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What is the gray that I see on the panels? Primer. I hope you drilled holes in it!
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Too many projects, not enough time.
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Jun 10, 2020 14:13:50 GMT
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I hope you drilled holes in it! No, but I sprayed from twice the recommended distance :-) Anyone would think that I was obsessed with weight reduction.
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Jun 10, 2020 16:36:09 GMT
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I hope you drilled holes in it! No, but I sprayed from twice the recommended distance :-) Anyone would think that I was obsessed with weight reduction. the rest of us KNOW you are
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Jun 10, 2020 17:35:48 GMT
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What is the gray that I see on the panels? Primer. Not having done body and paint on a composite body, was wondering what kind of primer you would put on carbon? Is this a epoxy that you will build upon with a high fill or is it the high fill itself or some special formulation for composite adhesion? If proprietary information, please disregard.
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Jun 10, 2020 17:38:05 GMT
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Not having done body and paint on a composite body, was wondering what kind of primer you would put on carbon? Is this a epoxy that you will build upon with a high fill or is it the high fill itself or some special formulation for composite adhesion? If proprietary information, please disregard. I could tell you, but then I would have to kill you! :-) Actually, just UPOL grey primer.
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bstardchild
Club Retro Rides Member
Posts: 14,937
Club RR Member Number: 71
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Jun 10, 2020 19:27:28 GMT
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Not having done body and paint on a composite body, was wondering what kind of primer you would put on carbon? Is this a epoxy that you will build upon with a high fill or is it the high fill itself or some special formulation for composite adhesion? If proprietary information, please disregard. I could tell you, but then I would have to kill you! :-) Actually, just UPOL grey primer.
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