Carbon fibre ramps for car bench

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#1

Hello,

We made some full CF ramps for a car bench.
We made them with a 15mm sandwich core. The sandwichmaterial is 3D Core PET100.
The length is 2200mm, the wide is 500mm and the edges are 70mm high. The laminate thickness without core is 8mm.

The layup is:

  1. layer: 193 g7m² Spread Tow HP Textiles
    2-4 layer: 1070g/m² quadraxial
    sandwichmaterial: 3D Core PET 100
    5-6 layer 1070g/m² quad Seartex Airbus
    7+8 layer 400g/m² UD HP
    9 layer 1070g/m² quadraxial
    resin: R&G resin L / hardener GL2

The whole layup was made in one shoot with the MTI resin infusion.

First we waxed the metal mould, than we sprayed PVA. The first layer in the mould is the IMC from HP Textiles, a polyurethan In Mould Coating. The IMC was also sprayed.

The first fabric layer is a 193g/m² Spread Tow twill, layed with a V

followed by 3 layers of 1070g/m² non crimped quadraxial CF Fabric

We choosed the 3D Core as sandwich material. It is very stiff after infusion, the PET100 is very pressure stabil and it has less resin consumption combined with a very good resin flow.

Here some informations
http://www.3d-core.com/en/products/products_range.html

and some pictures

Followed by 2 further layers of 1070g/m² quadraxial

#2

Than we layed a layer of 400g/m² unidirectional and a last layer of 1070g/m² quadraxial. Sorry but I forgott to make photos of these two layers.

Where the sandwichmaterial was placed we also placed 4 M8 Big Heads for fixing the hinge. (also forgott to make phostos, sorry.

Now we go on with the infusion setup. First a peelply

followed by a perforated release film.

and the flow media

not to forget the most important thing for a perfect result, the MTI hose

Than place a spiral tube as resin inlet in the middle an seal it with a bag.

Now we can mix the resin and degas it. As you can see first there are only a few airbubbles amd after e few minutes there are some more.

#3

After degasing we can start the infusion. My resin inlet tube has a inner diameter of 6.5mm and we have to infuse about 10kg of resin.

Resin stops at the MTI hose and goes on through the dry fabric.

You also don’t have to be careful with laying the flew media, On the right side are about 50mm space between flew media and MTI hose, on the left side is no space. But because of the MTI hose that is no problem.

after infusion when all fabrics are wetted out there are no airbubbles in the flow media.

Thats because of the closed system you have so that no resin can travel out of the mould. We calculated the resin we will need if we want to reach a fibre to volume ratio of 55% and thats the resin we infused. But don’t forget the other things with resin consumption like flow media, peelply…
I used the seartex material calculator, here the link

http://www.saertex.com/produkt_technik/technik/materialrechner/

We reached a calculated VF of 55%

48h later this is the result

No pinholes or airbubbles, a perfect surface. The matt finish is because of the wax and the PVA that is stil on the part.

Here can you see the trimmed and untrimmed part.

#4

and the mounted ramps on the car bench

with a AMD CLK63 Black Series on the middle of the ramps you can’t see any deflection (I know that it is too heavy, but the customer does not want any deflection.)

They weight of each ramp is 17kg ready to mount.

#5

Wow that is sick!!! I love these ramps!!! Great Idea!!!

#6

+1 I can’t believe I havn’t seen this done yet. Nice job.

#7

Super idea they look great

#8

fat twill, nice!

#9

This is super rad. Thanks for sharing.

#10

Nice job! Deffinately and attention grabber eh?

#11

Yes, everybody looks at the ramps,but for a normal car repair they might be a bit too expensive.
I hope I will get a photo with an Enzo on the ramps, that would be nice.

#12

Very nice job!

#13

Very cool!

#14

Lol, that sick:D very expensive ramps :bigsmile:
Good job!!!

#15

Here the picture with the Enzo FXX

#16

Just great , by the way… How you managed to trim fiber in such straight line ? usually some fibers go off while trimming raw material

#17

Nice, can I also order a picture of these ramps with a Bugatti Veyron on them? :slight_smile:

#18

If you want I will post one, may take a few days :wink:

#19

then I book for a Zonda or Huayra :slight_smile: the state of art :slight_smile:

#20

Sorry, I can only offer a Carrera GT, a Koenigsegg CCX or a MC12 Corsa:p
No Bugatti or Pagani available at the moment.
As you can see the sticker at the ramps it is at edo-competition. They are a tuner for sports cars.