Lotus Europa Community
Lotus Europa Forums => Resources, Parts and Products => Topic started by: Chuck Nukem on Saturday,April 13, 2024, 06:40:59 AM
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I want to start a thread to cover the manufacture of molds, and demonstrate the practical implementation of carbon fiber in these cars. So far I have made a mold for the TCS rear decklid and spoiler. I am getting a hand from a friend with the molding of S1 Doors. He has many years of mold building experience, and you can really tell if you compare it to my solo attempts! I picked the S1 doors because they are probably the most challenging parts to make, and in my opinion are the best looking on any Europa. I also think a carbon/kevlar/honeycomb door panel, besides adding a nice look to the interior, is probably not a bad idea on these little cars in the age of giant trucks and SUV.
If anyone else has a current mold or carbon project going feel free to contribute here!
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Very interesting project. Please tell more. Is the green a colored resin layer? The fibers look like glass (white). Is that a first layer before the carbon?
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Great stuff, Chuck!!! :beerchug:
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The doors in the first pictures are from my S1. The flanging was staged around them to serve as the mold flange surface. The green paint is a tooling gel coat which serves as a hard outer skin of the mold which is what the carbon gets laid on later to become a new door. The initial fiberglass is used to build the mold surface. The next steps will be a wood bracing which will help to keep the mold in shape. Once we finish the inside surface, the flange is peeled away and the outer surface of the mold is made. Stay tuned!!
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It was confusing at first looking at the progression of the mold pictures from the top to the bottom, completion to initial mockup. This is absolutely great stuff. I was looking at making making a lot more simpler stuff then the S1 doors. I was thinking of CF air boxes and dashboards. Keep these projects coming, love it.
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Great work again!
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We are getting closer. The backside mold is complete. Now only the front side remains!
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More great stuff, Chuck!! :beerchug:
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Thanks BDA!
I think I'll just leave these photos here for everyone's thoughts on the matter.... :)
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No contest!
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Excellent!
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Nicely done! :pirate:
What was the final weight savings on the doors?
Tom
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Nicely done! :pirate:
What was the final weight savings on the doors?
Tom
We are still working on the molds. These are just pictures I found of a TC wearing S1 doors to show the difference. Without glass and window motors I am expecting at least 30-40 lbs? It will be fun to see. I think we are probably a month away from pulling parts.