"Forged" Carbon Fiber Isn't 

the ham sandwich was added to stick the vehicle to the ground, because as we all know, pigs don't fly

I shall send you a new JerryRig knife.

I've never been more honored to replace a resin-infused ham sandwich

I LOVE the fact that you started super strong and immediately jumped ship when you ran out of precut fibers, and just started sticking random shop junk in the composite. That's exactly how all my projects go; ambitious, logically designed, and completely randomly assembled depending on my level of motivation.

The best way to stop people saying "you did it wrong" is to intentionally do it like 40% wrong and give the design another safety factor of 2.5

the fact that the incompetent comment ended up right next to the fucking ham sandwich that you had to dig out is just pure comedy 😂

'Printed it 0.7% bigger'. My Uncle used to hand sculpt sand cast masters. He said it took many revisions to the mold to get the final dimensions correct for the same reason. When you/Matt said 'printed it 7/10s of 1% bigger I just imagined the amount tme and work that kind of adjustment used to take. Such a cool time to be alive.

Strong "Just Rolled In" vibe to this episode, especially when replacing the ham sandwich with spray foam.

i was in physical pain at some points, top notch youtube content

When i tought this could not get more unhinged, the sandwich came in...

Matt, that small triangular piece in front of vertical stabilizer is a leading edge root extension. At high yaw angle it creates a stron Vortex that energies the airflow impacting the main stabilizer increasing the critical angle of attack thus preventing a stall and increasing directional stability. The same principle is used in many modern fighter jets in front of main wings - F18s etc. When pulling hard manouvers you can observe vortices shedding and condensation on the main wing. Notice how they are still attached to the wing even at extremely high angles of attack. It is important to encorporate this design into your land speed car as it will help you not spin ass forwards

I have 45 years working with composites, and I have to say this was just brilliant, a perfect example of "fuck about and find out". Brilliant. The part looked totally acceptable in a Picasso kind of way.

"Guessing is enough engineering for me" is the motto of engineering students everywhere

Aerospace engineering student here - that 'transition' piece in front of the vertical stabilizer is not for drag reduction, it is for stability in a stall-spin scenario, or rather, it prevents a stall spin from developing. Cars obviously don't have aerodynamic stalls, but it adds area to your vertical stabilizer so it will help you track straighter. And it looks cool!

We hammered and pried then remembered it was screwed together . This is my new favorite channel

Forged is stronged for complex shapes that you dont have a custom weaved mat for. The chopped fiber soup gives a random layout that helps prevent weak points caused by poor weave alignment in the mat with complex geometries. You could layer multiple standard weave mats in the correct orientation for each section of part, but that adds weight and thickness for the overlaps. You can also make custom weaves so that it aligns with the part geometry, but that adds a lot of cost and complexity.

This feels like an April Fools video. I seriously hope you have something even more hilarious in store for April 1st!

Haminar flow

it always makes me happy to see composites done right

A Mike Patey video on his "Scrappy" bush plane aircraft build in carbon fibre showed fibreglass being used between metal components and the carbon fibre to prevent corrosion - food for thought. Mike Patey builds awesome race planes and other aircraft projects. Very gifted individual.

genius matt, the ham sandwich will be cured in the salt flat, making it inert.

You created the composite of all composites: Resin, carbon, paper, rage, foam, steel, aluminum, and ham

This is genuinely my favorite video you've made, this is commitment to the bit on a whole new level.

I've watched countless videos from countless RU-vid channels. Some really great content. This is the first channel I might become a patreon member. Such great stuff

I half expected the ham sandwich to absorb the resin like a sponge and become the strongest section.

this makes me happy. i always assumed that the weave pattern is what in part adds strength.

After everything you still managed to catch me off guard with the last second 10mm socket, lol

I felt the Matt/matte joke coming about 0.6 seconds before it landed, and I have concluded that is the optimal timing for maximum pun pain. Well done.

That superfast matte pun was top tier.

As usual, love it! Thanks for making these videos for us!

Those intermediaries are, if I remember correctly, actually pretty much an extension to the vertical stabilizer. Early P-51D's had issues with yaw stability due to transitioning from a razorback design to a flush bubble canopy, so later variants would extend the base of the vertical stabilizer to regain it.

You would think a ham sandwich was the weirdest thing added to a layup, but I know of a boat with a guy's grandmother's ashes mixed into the resin.

My old VP of engineering was a smart dude. We were ME/EE/FW engineers for hire and had to design things fast and reliably. He said, to be confident in your design you should have at least one of these: 1. Experimental proof that it works (TIW) 2. Robust simulation TIW 3. An expert says TIW and why 4. Someone else who actually researched it does it that same way. 5. If it’s fucked you can easily pivot to something else that works (but is probably more expensive) So your stabilizer transition thing is legit under article 4!

In the "High End" Cycling world (specifically by Trek Bicycles) it has been called "OCLV", or Optimum Compaction, Low Void. We always called it "Optimum Cracking Low Value" as it had a far higher failure rate than a standard weave.

400k sub! Congratz!

Not gonna lie, had to check to make sure it wasn’t April 1st half way through the video.

"....Because it's hilarious"... yes, yes it is. You made me leak from my eyeballs.

OMG good sir, I haven't laughed that hard in a looooongggg time! Kudos and keep up the exceptionally high quality work my friend!!!!

For better or worse, this video was my introduction to your channel. The part of me that is meticulous to a fault hated so, so much of this... But the part of me that appreciates dry, cynical humor convinced the other part to go take a nap so I could be entertained. Then I saw the Viper... Very cool. It's the kind of crazy thing I'd have loved to do in a video game. Here, you've done it in real life. I'm now subscribed.

You joke about engineered wood but plain OSB walls in the utility room is becoming trendy

"But that is a problem for future Matt" seems to be your favorite words!

I love your choices of words for the titles, but I'm interested in the subject too! :)

This is top notch work! I love how fast it went from doing everything right to doing everything wrong 😂

Adding tungsten to lightweight carbon - good thinking, Matt.

The 10mm socket joke… so obvious but so, so good. You sir are very good at what you do.

'Engineered wood' includes a lot more than just OSB, MDF and chipboard. Plywood, LVL (Laminated Veneer Lumber'), Blockboard, CLT ( Cross Laminated Timber), fancy finger-jointed window frames, Glulam beams. It may be kind of crummy at the bottom end (actually OSB is generally amazing) but the nice stuff really is engineered quite a lot and has impressive characteristics. But well done on the silliness of filling your forged part with random crap. Classic.

Always enjoy your story but this was the most fun so far and that is saying a lot. Thanks.

Engineering is about optimising. Optimising for performance, for durability, for cost, for ease of use, etc... Sometimes one of the optimisation factors is humour...

I’ve found that wetting the fibres out by mixing them in resin before inserting them into the mould is pretty much essential to achieve a full wet out on larger components

Gold, pure gold. Thanks for the laughs today! Loved it.

never watched your videos before but i effing love every bit of this

You sir, are a legend. I enjoy the subtle jokes, never ham fisted - they are the bread and butter of the channel.

It’s like the part is an embodied shitpost to grief your haters. I loved it. It also looks pretty cool.

1:11 It keeps the air attaches to the rudder at high yaw angles, like a LERX. The high sweep virtually decreases the Angle of Attack to the incoming airflow, lowering the chances of stall. At very high angles, it may even generate a vortex, with similar positive effects. Structurally, it increases the contact area with the fuselage, securing the rudder in its place. As for forged carbon, it was conceived to eliminate the manual labor involved in normal carbon fiber manufacturing, lowering its cost. It's called "forged" because it supposed to be pressed on the mold by a press-forge, which would also cure it. It's a strong material, but not as strong as regular carbon fiber. But it surely looks shiny and glamorous.

I remember a story about the first dehavilland plane to use bonded aluminum panels and how the old school workers really didn’t understand that while a clean room would be and ideal place to have lunch a composite clean room definitely isn’t. The aftermath : debond and corrosion issues. The linen scrim used in early adhesives also didn’t help. I haven’t laughed that hard for days! A mostly adequate job sir!

The transition from the fuselage to the vertical tail has no aerodynamic advantage. A professor in engineering school told us it was the result of needing to increase the tail area for lateral stability after the initial design and/or test flights were performed. It was cheaper to add this structure than redesign the empennage completely. It may also allow a lower tail height to reduce roll coupling.

that 10mm socket caught me of guard

That little extension to the vertical stabilizer was often added to increase directional stability in aircraft. You can see it being added in the later P-47 models. Also reduces drag!

I just discovered this channel and i really wasn‘t ready for this

One of these days, future Matt is gonna beat the crap out of past Matt.

Dear lord, i feel bad for what that guy Future Matt will have to endure...

That additional transition is installed to increase fuselage surface area to reduce tail wagging . They first appeared in the NA P51 D Mustang during WW2 . You can buy the thin PTFE impregnated glass fibre sheet at the cheap supermarkets as baking sheet used in domestic ovens . There is a thicker black coloured sheet too . I use it for moulding and for high tech gaskets in engines .

laughing out loud, big smiles, and I hope I'm not waking anyone up, but I can't help it... loved the video!

The only thing I can think you've done wrong in this build Matt is not re-forging the "good enough" sticker, but that "Superfast Matt" paint is pure freaking gold bro.

The sandwich brainfart. Were you trained at Boeing by any chance?? All hail the algorithm.

Absolute video perfection like usual!

The added fin-like transition piece on many airplanes, usually on the vertical stabilizer (commonly referred to as the "rudder")...is called a "fillet". It is added to add surface area to the vertical stabilizer, without adding height to the "fin" (which might not always be practical). What it does is improve directional stability - in "yaw" (which is the horizontal plane). If you see an early version of an aircraft, without one....then a later version, with a fillet added...you can bet that the early version did not display enough (yaw) directional stability. Fillets can be added to any of the tail surfaces, both horizontal stabilizers (elevators) and vertical (rudder), if needed. Most often, though, they are added to the vertical stabilizer.

The intermediate part before the rudder is a vortice generator exactly like a delta wing, it causes a large notice to generate at high angles which increases drag in the back of the aircraft and increases the stabilizing lift force by up to 80pct over just having the plain rudder alone. This was discovered around the time of WW2 but not understood at all until the 60s, by the 70s it was being built into the strakes of combat jets like the f-16 and f-18

Aside from the sandwich, the other inclusions are actually really cool looking and i liked them a lot.

"Guessing is enough engineering for me" I have not laughed this hard in ages. I mamaged a lodge in Africa some years ago and fixing shit often had me thinking pretty much the same way. Stay awesome

I don’t think I’ve ever subscribed to a channel after seeing only one video until today.

The long transition-y bit is a leading-edge root extension, they help keep the wing (or tail) un-stalled at higher angles of attack. On fast jets they're usually on the wing and result in being able to do more top gun type things; on slow jets on the tail, I think they help prevent and recover from spins and other 'stalled tail' situations where there's a big apparent crosswind, which is potentially a very bad day. On the land speed car, I *hope* the plan is to not run it with a 90mph crosswind (seems sketchy but idk) so it should be less of an aerodynamic factor and more of a coolness-enhancing one; there might be some benefits to moving the tail's centre of pressure a bit lower. A short literature search has turned up nothing on the merits of a ham sandwich for yaw stability, but I hope the Ig Nobel committee is paying attention.

Fun fact: the main reason most GA aircraft's vertical stabilizers aren't just rectangular in planform is that marketing found that tapered and swept vertical stabilizers sold better. For manufacturers like Mooney the tail profile is simply part of the brand image, like how BMW uses kidney grilles. All that being said, the dorsal fin does help keep the vertical stabilizer from stalling at high side slip angles.

The extras to fill was Epic !

When you added the sandwiches, I actually saw it coming, I knew the moment I saw them that you were going to put them into the mold, however I didn't think you'd actually leave them there! I thought it was just going to be a gag, but nope, you actually let it cure like that. I really thought at that point you were going to fully commit, until it rotted and forced you to dig it out, but at least you didn't do that. Top notch content.

Matt your "close enough" method is absolutely hilarious.

I haven't laughed this hard at the internet in a long time. Thanks SuperfastMatt!

Got a mint 2015 gmc truck recently. The full deluxe package and a fancy engine. Might do this for bumper covers. Wont do much in a crash, but I wont have to worry about dings.

First video I saw I wasnt sure. This second video just makes me giggle. Love the way you mess with everyone, including yourself. 🤣

Matt, from the bottom of my heart: THANK YOU! that hilarious video was just what i needed after this week! Edit: Okay, i didnt see the "superfastMATT" and the 10mill joke coming at the end, but boy, those were great :D

Brilliant - you continue to be my favourite channel, by producing hilarious and off the wall content, yet somehow producing working vehicles...

Dorsal fin is not a drag reduction feature. It creates a vortex during high angle of slips which delay the boundary layer separation, thus prevents early stall on the stabilizer.

Went into this video expecting frustration, came out with a huge smile. Thanks Matt!

That actually looks pretty cool. I thought the forged carbon fiber was also supposed to be "thin" like normal carbon fiber, with either a foam core, no core (hollow) and/or bonded to a complimentary stiffening piece like car hoods.

This is peak content. Glad you found my 10 mil, too!

Oh... My... God....

Important lesson learnt, dehumidify then degas ham sandwiches before adding them to resin composites.

The fact that you're talking about cool stuff is almost a bonus. Your dry humour makes almost anything worth listening to.

The 10mm is amazing. I'm missing at least 3 I think. Although one isn't really missing it's just stuck in the frame rail of a car I sold years ago.

The superfast matt paint job is absolutely some of your best humor.

All of my garage/work shop walls and ceiling are OSB. I can hang a nail or a shelf anywhere I want without looking for a stud, and it's much more durable than drywall. Additionally, our utility/laundry room is a psuedo-tornado shelter with two layers of 3/4" OSB subflooring. Skim-coated it with a couple of thin coats of drywall mud and it looks just like sheetrock but WAY stronger. So, yay for forged wood...

Hilarious and really cool at the same time! Great job mate

Hey Matt, the strake forward of the vertical stabilizer is for stability at high yaw angles. It generates a vortex that keeps the flow attached on the low pressure side. Source: Aerodynamics for naval aviators.

The end product looks really clean, hilarious!

I have no idea what your channel is about, but the way you presented this and the humor just made subscribe anyway.

Easily one of your best RU-vid videos so far, and that's saying something.

So its more of a "forgery" forging than a "highly compressed molten metal" forged. I was also very intrigued to hear your 3D print shrank, because we've been experiencing the same thing at work. Every part that needs a dimension held was coming out tight.

I love your dry sort of humor and would like to have my posting glued inside one of your artworks. At last I like most the story from the pikes peak, allaround. my garage is also full of projects and I watch your videos, which are grat!, and hope to find some inspiration and motivation. hand

I have never laughed so hard at a racecar build video. Thank you for making such fun videos!

this made my day, i wish more people had a sense of humor like you.