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CUSTOMER GALLERY

USED IN THIS PROJECT

Although not necessarily an exhaustive list, the following tools and materials, supplied by Easy Composites, were used in this project.

The quantity shown below is the approximate amount used in the project rounded up to the nearest available kit size or quantity.

MATERIALS & CONSUMABLES
ET538 Honeycomb Bonding Epoxy Adhesive 400ml Twin Tube Thumbnail
ET538-400ET538 Honeycomb Bonding Epoxy Adhesive 400ml Twin Tube£49.95 /each

PT326 20min Rigid Polyurethane Adhesive 400ml Twin Tube Thumbnail
PT326-400PT326 20min Rigid Polyurethane Adhesive 400ml Twin Tube£49.95 /each

Total £0.00
REINFORCEMENTS
XT135/S 250g 3k Tooling Prepreg Carbon (1250mm) 10m Roll Thumbnail
XT135S-C311T2-250(1250)-10mXT135/S 250g 3k Tooling Prepreg Carbon (1250mm) 10m Roll£594.80 /roll

Total £0.00
PATTERN MAKING MATERIALS
EP700 High Temp Epoxy Tooling Board T=100mm, 500 x 500mm Thumbnail
EB700-025-100EP700 High Temp Epoxy Tooling Board T=100mm, 500 x 500mm£196.95 /block

Total £0.00
MOULD MAKING MATERIALS
AS40 Addition Cure Silicone Rubber 5kg Kit Thumbnail
AS40-5AS40 Addition Cure Silicone Rubber 5kg Kit£75.75 /kit

Total £0.00

CUSTOMER GALLERY

Prototype Twin Element Front Wing Package

After months of development, and over 2000 hours of work, Martin completed the prototype twin element front wing package. This package is an optional upgrade for Unzipped's modular front splitter. These wings are made entirely to suit customer cars without the massive costs of developing a custom one-off setup.

Designed in-house using OpenFOAM 2D CFD simulation, we started with a well known and proven ground-effect NACA airfoil profile and modified its camber in order to achieve a static pressure distribution that maximises downforce whilst minimising the downstream impact this has on the rest of the car.

The patterns for the aerofoils, end caps, and diffusers were all CNC milled from epoxy tooling board. The main spar mould was made with XT135 tooling Prepreg. The end cap moulds were made with AS40 silicone, while the end caps themselves were cast with epoxy and chopped carbon reinforcement.

The wing itself is constructed entirely from XC110 pre-preg carbon fibre as a hollow body with a structural main spar bearing most of the load, and strategically placed aluminium honeycomb and Rohacell foam core for maximum rigidity at minimum weight - the entire thing, at over 2000mm's wide and 800mm's deep, weighed in at just 9.3kg and is able to withstand 1000kg of aero loading.

The end plates are XC110 skins with Nomex honeycomb cores and aluminium solid mounting points. M10 BigHead threaded rods were used as the main mounting points for the entire wing. Structural bonding was a combination of Permabond ET538, PT326, and XC130 resin film.

Thanks for sharing your project with us Martin - it looks amazing!


ABOUT UNZIPPED COMPOSITES

Unzipped Composites

Unzipped Composites was formed in 2013 by Martin Hanbury.

A motoring enthusiast and keen DIY-er, Martin found that when modifying imports, carbon fibre is something that is quite often required.

After feeling continually dissatisfied with the quality of commercially available carbon fibre components, Martin decided to try his hand at fabricating his own and immediately knew he had found another passion.


CONTACT INFORMATION
Websitewww.unzippedcomposites.com
Instagram@unzipped_composites

USED IN THIS PROJECT

Although not necessarily an exhaustive list, the following tools and materials, supplied by Easy Composites, were used in this project.

The quantity shown below is the approximate amount used in the project rounded up to the nearest available kit size or quantity.

MATERIALS & CONSUMABLES
ET538 Honeycomb Bonding Epoxy Adhesive 400ml Twin Tube Thumbnail
ET538-400ET538 Honeycomb Bonding Epoxy Adhesive 400ml Twin Tube£49.95 /each

PT326 20min Rigid Polyurethane Adhesive 400ml Twin Tube Thumbnail
PT326-400PT326 20min Rigid Polyurethane Adhesive 400ml Twin Tube£49.95 /each

Total £0.00
REINFORCEMENTS
XT135/S 250g 3k Tooling Prepreg Carbon (1250mm) 10m Roll Thumbnail
XT135S-C311T2-250(1250)-10mXT135/S 250g 3k Tooling Prepreg Carbon (1250mm) 10m Roll£594.80 /roll

Total £0.00
PATTERN MAKING MATERIALS
EP700 High Temp Epoxy Tooling Board T=100mm, 500 x 500mm Thumbnail
EB700-025-100EP700 High Temp Epoxy Tooling Board T=100mm, 500 x 500mm£196.95 /block

Total £0.00
MOULD MAKING MATERIALS
AS40 Addition Cure Silicone Rubber 5kg Kit Thumbnail
AS40-5AS40 Addition Cure Silicone Rubber 5kg Kit£75.75 /kit

Total £0.00

ABOUT UNZIPPED COMPOSITES

Unzipped Composites

Unzipped Composites was formed in 2013 by Martin Hanbury.

A motoring enthusiast and keen DIY-er, Martin found that when modifying imports, carbon fibre is something that is quite often required.

After feeling continually dissatisfied with the quality of commercially available carbon fibre components, Martin decided to try his hand at fabricating his own and immediately knew he had found another passion.


CONTACT INFORMATION
Facebookwww.facebook.com/unzippedcomposites
Websitewww.unzippedcomposites.com
Instagram@unzipped_composites

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