bit of an update.

Been slowly learning CAD to get my design shape down roughly.

So its time to test some materials! I'm looking at either using a 20mm or 10mm foam or alloy honeycomb core material with carbon either side.

So this was a practical but not extremely scientific test of a sample panel i have made. This panel was made of 2mm carbon fibre, 20mm aluminium honeycomb and another 2mm of carbon.

I expected it to be a massive overkill from other carbon tubs ive seen, but Ive done it for a bench mark.

First of all put it between bricks and got me and my mate to jump on it - no visible damage and no visible deflection while loaded

so i thought "fuck it" and decided to run it over with my 4x4 bear in mind the weight distribution is such that the front wheel i used was loaded to about 500kg spread over the tyre contact patch.

The test piece is 50cm by 30cm.

Test one - simple drive on it:

no measurable deflection and no visible damage afterwards.

Time to up the anti.....

Prop it on a brick against the kerb, and drive onto it like a ramp:

about 3-5mm measurable elastic deflection. No structural damages except minor gouges on surface of carbon where it rested on the brick and ground.

So up anti again and just rest on the kerb:

Almost identical results to above.

Proof it is a heavy 4x4 and not a mini:


The final test, put it between 2 bricks and drop off the kerb heavily. See how it does with a bit pf shock loading!!

The defelection was permenant this time with the shock loading! No obvious cracking in the carbon but the honeycomb does appear crushed in places.

Although not massively scientific, has confirmed that a 20mm core is overkill for the main parts of the chassis and 10mm is likely to be plenty. 20mm will be reserved for the high loading members.