[BUILD] F3 Sidepod Cover Build 

The manufacture of a Formula 3 sidepod cooling opening cover for a Dallara F307 (2007) using fibreglass with a foam core by the infusion method.
Core Nail Press Punch build video here: • [BUILD] Nail Press Punch
The build starts at 2:11
The lessons learned start at 12:21
Check out my website, if you have any projects you want help on hit me up and we shall see what we can do. www.chapmaneng.com
The infusion connector is available here: www.ebay.com.a...
This part is to replace the one that I previously manufactured which was damaged beyond repair (just look at that thumbnail image!). From what the owner was able to tell me, the forward bolts were left out after a repaint/wrap and when on the track the cover folded in half, this caused the hot exhaust gas to melt/burn all of the matrix out of the composite leaving what was essentially raw fibreglass behind. It was actually kind of cool to have a look at, definitely a very interesting failure mode.
As always when doing this kind of work, make sure that you use appropriate PPE, store the chemicals properly (both in an absolute sense for your safety, as well as in accordance with your local laws and regulations) and be mindful of dust generation and removal.
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Materials:
- Resins:
Kinetix R246/H126 Laminating Epoxy (it infuses fine for small parts)
- Fabrics:
Easy Composites 200GSM 2x2 Twill Glass
Trojan Composites 160GSM 25mm Glass Tape
- Core:
Easy Composites 75kg/m3, 3mm, EASYCELL75 PVC Foam
Assorted other consumables and the like, leave me a comment if you want some more details.
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Soundtrack by bensound.com
- Adventure
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