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Lightyear Composites

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    Lightyear Composites

    I thought I would post up things I am working on. If there is interest I will keep updating.

    I started making carbon fibre parts about 8-9 years ago as I couldn't buy the bits I wanted. I was shown the basics by Dick down in Torquay. And the rest I learned from trial and error. Most parts I make are vacuum infused carbon fibre.
    The current projects are the Fastback roof and boot for the MX5. And the big race wing.

    Today I made the first 300mm main cord element. It turned out pretty good for a first try.



    [url=https://postimg.org/image/5xvq7b3b9/][img]https://s26.postimg.org/wiy92v5op/image

    It passed the initial test- put blocks of timber under the ends and stand in the middle. I made it about 1670 wide, the width of an MX5 body. I will test it on the track, and make the 2nd smaller element to get some data. The wing feels so strong, maybe too strong. I could have built it lighter, but at least you know it will never fail. The total weight is 3.4kg's. Not super light, but not bad. I can save some weight by making the endplates 6mm. I made them much thicker incase someone want to mount the wing by the ends.
    NA8B 89KW- P.I. 1:50.1, WNTN1:38.0, SDWN 1:27.6, WKFLD 1:10.4
    NB8B 181KW- P.I 1:43.8, WNTN 1:32.9, SDWN 1:22.0, BDFD 1:05.3
    VP 293KW- P.I 1:43.8 WNTN 1:33.5

    #2
    You sure are a handy bugger light year its no wonder your so successful, and can steer as well.
    Nice work and show us the trophy at the next commadore outing.

    Comment


      #3
      Cheers, I hope the car is good enough to get a trophy at Winton. To make sure I am getting some better diff gears installed on Monday. And will look for some used slicks. That should give me half a chance of keeping up.
      NA8B 89KW- P.I. 1:50.1, WNTN1:38.0, SDWN 1:27.6, WKFLD 1:10.4
      NB8B 181KW- P.I 1:43.8, WNTN 1:32.9, SDWN 1:22.0, BDFD 1:05.3
      VP 293KW- P.I 1:43.8 WNTN 1:33.5

      Comment


        #4
        Are the ends aluminium, were they CNC or can you buy them? Does the wing bow when you stand on it or were you just trying to make sure it doesn't snap?

        Looks good mate.
        GAS 260Z RB26DET
        GAS 1600 3SGE BEAMS

        Comment


          #5
          There is zero deflection when I stand on it ~90kg's. It feels every bit as strong as steel. The ends are water jet cut alloy drawn up by me and then cad drawn over several attempts by others. Inside is high density foam cut by a foam cutter using the same cad drawings. The alloy bits do add a decent chunk of weight. So I will make them 6mm if they are not going to support the wing.
          I can try take a pic with a couple of guys standing on it. It's crazy how strong it actually is. I have no concerns about it breaking or even flexing.
          NA8B 89KW- P.I. 1:50.1, WNTN1:38.0, SDWN 1:27.6, WKFLD 1:10.4
          NB8B 181KW- P.I 1:43.8, WNTN 1:32.9, SDWN 1:22.0, BDFD 1:05.3
          VP 293KW- P.I 1:43.8 WNTN 1:33.5

          Comment


            #6
            Awesome. Actually sounds much stiffer than steel. Well done.
            GAS 260Z RB26DET
            GAS 1600 3SGE BEAMS

            Comment


              #7
              Keen on wing. How wide can you go? Would like 1800 or maybe wider. Can you put the mounts at the spacings I want too?

              PM me some prices :)

              Comment


                #8
                I can go about 1950mm Max. Every wing can/will be custom made to suit the required widths. Mounts can be done by me. I haven't worked out prices yet, I will make another one and write note all the time/costs involved.
                NA8B 89KW- P.I. 1:50.1, WNTN1:38.0, SDWN 1:27.6, WKFLD 1:10.4
                NB8B 181KW- P.I 1:43.8, WNTN 1:32.9, SDWN 1:22.0, BDFD 1:05.3
                VP 293KW- P.I 1:43.8 WNTN 1:33.5

                Comment


                  #9
                  I am making a standard shaped vacuum infused carbon fibre MX5 hardtop. I will show you guys what is involved. It's not a step by step how to, rather just showing the process, and how much work goes into it.

                  To start, clean and prep the mould.
                  NA8B 89KW- P.I. 1:50.1, WNTN1:38.0, SDWN 1:27.6, WKFLD 1:10.4
                  NB8B 181KW- P.I 1:43.8, WNTN 1:32.9, SDWN 1:22.0, BDFD 1:05.3
                  VP 293KW- P.I 1:43.8 WNTN 1:33.5

                  Comment


                    #10
                    Next spray a mist of tacky spray, cut the cloth and lay it in the mould.

                    NA8B 89KW- P.I. 1:50.1, WNTN1:38.0, SDWN 1:27.6, WKFLD 1:10.4
                    NB8B 181KW- P.I 1:43.8, WNTN 1:32.9, SDWN 1:22.0, BDFD 1:05.3
                    VP 293KW- P.I 1:43.8 WNTN 1:33.5

                    Comment


                      #11
                      Then carefully push the cloth into all the shapes of the mould. Trying to keep the weave pattern running straight everywhere. Trim the excess. You might notice around the back the cloth doesn't line up, that's a second layer as it needs more strength there.

                      NA8B 89KW- P.I. 1:50.1, WNTN1:38.0, SDWN 1:27.6, WKFLD 1:10.4
                      NB8B 181KW- P.I 1:43.8, WNTN 1:32.9, SDWN 1:22.0, BDFD 1:05.3
                      VP 293KW- P.I 1:43.8 WNTN 1:33.5

                      Comment


                        #12
                        Core layer.
                        NA8B 89KW- P.I. 1:50.1, WNTN1:38.0, SDWN 1:27.6, WKFLD 1:10.4
                        NB8B 181KW- P.I 1:43.8, WNTN 1:32.9, SDWN 1:22.0, BDFD 1:05.3
                        VP 293KW- P.I 1:43.8 WNTN 1:33.5

                        Comment


                          #13
                          Another layer of carbon fibre is in, and a release layer over the top.
                          NA8B 89KW- P.I. 1:50.1, WNTN1:38.0, SDWN 1:27.6, WKFLD 1:10.4
                          NB8B 181KW- P.I 1:43.8, WNTN 1:32.9, SDWN 1:22.0, BDFD 1:05.3
                          VP 293KW- P.I 1:43.8 WNTN 1:33.5

                          Comment


                            #14
                            Next I put in the infusion mesh and infusion channel. Then tacky tape around the perimeter and place the plastic bag on, connect the lines and turn the pump on to suck out all the air.
                            Now the tricky part starts- finding all the air leaks..
                            NA8B 89KW- P.I. 1:50.1, WNTN1:38.0, SDWN 1:27.6, WKFLD 1:10.4
                            NB8B 181KW- P.I 1:43.8, WNTN 1:32.9, SDWN 1:22.0, BDFD 1:05.3
                            VP 293KW- P.I 1:43.8 WNTN 1:33.5

                            Comment


                              #15
                              That's cool to see how it's done :D

                              | 1963 RK43 Toyota Lite-Stout (Stanley) | 2002 EC5W Mitsubishi Legnum VR-4 Type-S (Larry) |


                              Originally posted by Gammaboy
                              PF - We're not happy till you're not happy.

                              Comment

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