Alex's FD3S
#1
Junior Member
Thread Starter
Alex's FD3S
Just putting the finishing touches to the carbon doors I made for my car so I thought I'd start a build thread.
Complete with (lightened) hinges and latch but no perspex, they each weigh in at just 3.5kg
Complete with (lightened) hinges and latch but no perspex, they each weigh in at just 3.5kg
#2
Junior Member
Thread Starter
It started with some really poor quality fibreglass doors I bought off ebay...
They looked OK, but were not at all up to the job. Far too flexible, the rubber around the top of the window was causing the side screens to flex out when the door was shut. They also sagged terribly when the doors were open.
They looked OK, but were not at all up to the job. Far too flexible, the rubber around the top of the window was causing the side screens to flex out when the door was shut. They also sagged terribly when the doors were open.
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#8
Junior Member
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Life's too short to be fiddling around up to your elbow inside a door trying to put a nut on. So, made up some captive nuts and brackets to bond onto the inner halves.
#11
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It's a '92 Japanese import. Race car/track toy/ongoing project. Currently weighs in at 1020kg with fluids.
- Pineapple Racing large street ported engine
- GT4088R turbo
- DTA S80 Pro ECU
- Race Technology data logging setup with CAN interface
- AP Racing complete brake setup (calipers, discs, pedal box, lines)
- Ohlins 2-way adjustable dampers
- Racing Beat aluminium flywheel
- 5.5" AP Racing Clutch
- Drenth DG400 heavy duty sequential g'box
- 4.77:1 final drive
- ATL 80L fuel cell in rear buckets
- Self-built carbon fibre nose, headlights, front wings, bonnet, front splitter, rocker panels & rear arches
- Custom cages T45 rollcage
- AP Racing air jacks
- Fibreglass rear hatch
- 10.5J 18" CE28Ns all round
Last edited by raceralexuk; 10-24-18 at 11:25 AM.
#16
Junior Member
Thread Starter
The bodywork was a whole project by it's self too. I spent a long time going through the same process as with the doors. Lots of foam, filler and a few tons of fibreglass got the moulds done. Making the panels is comparatively easy once it's reached that stage.
I don't work in composites, everything I've done has been self taught and took a lot of trial and error 🤣 A lot of stuff didn't work and had to be thrown away ($$$$$$$) just to figure out how to make it good in the end.
#18
Not the company
Couldn't have put a better response; this build is SERIOUSLY impressive. Amazing work!!! Subscribed to this thread for future updates for sure.
#20
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Thread Starter
Eventually I decided to lay up some very thin (2ply) carbon/kevlar as it's flexible. I cut it into strips and butt-joined with epoxy, then to give it some actual strength, I wet-laid two more layers on the reverse side.
Ran a bead of silicone along each of the joints and put rubbers round the edges to finish it off.
#21
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#23
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I don't actually have a picture of it completed off the car. Here's the bottom half. I made it so the nose attaches to it with 6 1/4 turn locks, and it's removed along with the nose in 30 seconds.
#24
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Thread Starter
I'm just trying to figure out how to fasten on the side windows. Previously I've used 5mm nuts and bolts, but I think there's a better solution. I've spotted some really nice looking fasteners on GT3 and GT4 Porsches.
I looked through some online catalogues for the Manthey Racing Cayman and spotted the drawing below. They're described as Cam-Lock fasteners. Can't find those exact ones though, does anyone know what they are and where to get them?
I looked through some online catalogues for the Manthey Racing Cayman and spotted the drawing below. They're described as Cam-Lock fasteners. Can't find those exact ones though, does anyone know what they are and where to get them?
#25
Junior Member
Thread Starter
Here are the headlights I've made. Would be able to produce more if I can work out how to make more clear covers - these ones are doners from another headlight kit.