nose job formula atlantic

General Composites Discussions Showcase
#1

I never did one but they asked me if I could build it. I’m always up for a challenge
It took me a while to think this through but here is how I did it.
The mold was in bad shape. I had to repair it and make a few changes to the flanges.
It’s for a RALT RT-40 Formula Atlantic
First I ordered some 3/8” aluminum honeycomb from Texas Almet and I made the mistake of choosing a little too stiff stuff so I had to cut it into sections and vacuum bag form it to shape.
Then I sprayed it with white Duratec gel-coat and using PTM&W 2050 (I love that stuff) laid up 1 ply 2x2 C/F. I did not want to draw vacuum thru the flanges with multiple cures. After that was cured I bonded in the sections of honeycomb with 1 ply 2x2 C/F , 1 ply crowfoot Kevlar, 1 ply 2x2 C/F. Potted in core splices and end features and wing attach pieces (alum tube bolt spacers at bottom)
The top plies 2 ea. 2x2 C/F, rear bulkhead 4 plies plain weave & it popped right out of the tool
After the pic’s I wet sanded it and buffed it (the car is white)

#2

That looks great!

#3

Looks great there. Where is your bag sealed to since you barely have a flange? Im assuming it’s sealed somewhere on the outside of the tool?

#4

:slight_smile: awesome work. Are you cooking in an oven? What adhesive did you use to print the core? I always have trouble getting cores to lay just right? Even 3/8 nomex would have given a good fight in those radiuses. Also I see no trace of the carbon falling into the cells. What was your method? Is that a working transducer? Are you adjusting vacuum after gas out? Honeycomb can be a devil I’m trying to figure what approach you took in achieving such a smooth inside surface… Unless you potted and skim coated for that.

I’ve cooked fiber film adhesive over nomex to get a smooth inside bond surface but it looks like you might have been a bit more creative. On flat surfaces I’ve also used cul Plates for core form and bonding but… How did you do it. Your edges look nice too…

Did you use silicone sheet??? It looks so smooth in there!!! :slight_smile:

#5

What i think you meant to say was “Tell me ALL THE THINGS!”

:wink:

#6

this one was all wet layup w/PTM&W 2050 (room temp). Prolly not the best way but it kept the cost down. The whole mold was bagged a few times to get it good nuff.
inside I just used a peel ply, air weave and bled it out.
I try not to over think it, just plan ahead for the worst.
since it was built the car got hit hard in the nose (@AA Speedway Fontana CA.), crushed well and did no other damage to the car.

(I have not logged on in a while, had surgery 2 weeks ago)

#7

That must be nice to know that if it was to get destroyed, it performed exactly like you’d want it to. How is the recovery from surgery treating you?

#8

it depleted a lot of energy
warning: working as a slave to composites can result in Carpal Tunnel Syndrome

#9

Tom, I aquired tennis elbow from composites … lots of hand finishing. My wife says she will buy me a brace for it tonight lol. I need some new air tools for less strain.

Nice work on the nose piece!

#10

Oh so this surgery was a long time coming then?

I guess will make an extra effort to keep my pneumatic tools in good order

#11

I’m already getting backaches from composites related activities and I’m in my early 20’s!