FEATURED PROJECTS
We were embedded in the design team from project start to ensure ease of manufacture using Vacuum Infusion, taking lead specifically on the bonnet, tailgate, passenger door, drivers doorcard and dash panel with all our CAD work being done in Rhino.
This allowed the parts to be produced using a combination of various materials and a ‘flexible’ epoxy resin system where required.
From design sign-off we took full responsibility for machining, tooling and manufacture of the parts.
We supply wheelarch liners, bonnet corners, HVAC parts, complete trimmed dash panels and door liners across Prodrive Hunter, Dacia and Defender programs.
A very demanding environment for any part in terms of loadings, abrasion and impact damage.
This is an environment particularly suited to our ability to use specific material/resin combinations to maximise the performance requirements of each part.
Starting from a scanned data set (organised and conducted under our direction) a completely new set of bodywork was developed in Rhino. The scanned panels, which had been very well made originally, were over 50 years old and time had taken its toll with some considerable differences from side to side. The final panels released for machining were as close to the originals as possible but symmetrical and surfaced using the tools available within Rhino.
The masters were machined using the data from Rhino, subsequently prepped and moulds made. The new panels were made exactly as per the originals. Hence the use of Papaya Gelcoat (colour provided by McLaren), various glass fabrics and a carbon mesh reinforcement, all applied to the moulds by hand. The carbon mesh represents the first method of using carbon fibre in a racing car (fabric had not been woven at this time) allowing for a considerable weight saving over a glass only item.
Our first off body was fitted to an original Team McLaren 1970 factory chassis and after appearing at Monterey Car Week now regularly races in historic Can-Am.
A one-off vehicle for OEM marketing/promotion for Subaru USA. We were responsible for all the carbon composite bodywork.
Design (to brief), masters, moulds and finished parts. All created by hand (no CAD available from Subaru) in ten weeks.
Front Bumper, Front Splitter, Bonnet, Front Fenders, Front/Rear Doorcards, Rear Doors, Rear Bumper.
The car ran at the Isle of Mann TT, The Nurburgring and the Transfagarasan Highway.
GT3 Vacuum infused cell boxes to FIA specification.
GT4 Robot machined OEM aluminium bonnets and fenderettes to provide extra cooling.
From 2020 we have supplied an epoxy/flax bonnet together with an epoxy/flax oil cooler duct to increase cooling further.