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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.
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.
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.