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Old 29th May 2013, 18:53
chrislandy chrislandy is offline
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Keep it simple and light, the layup you've got there iwill be about 1kg/m2 at least!

If you are going to gel it then I would do something like

Gel
tissue
200gsm woven glass
2mm coremat/cork
200gsm woven glass

You should be able to get it down to around 2.5-3mm thick and 0.5-0.6kg/m2

with localised sitffening/solid layup at mounting points, add an extra bit of core in a cross brace arrangement on larger panels such as the bonnet. You can use things like Bighead fasteners either bonded on after or layed into the laminate for most of the fixings.

If you can vac it down during the cure that will make it even better, if you are using polyester resin then limit the vac to around 0.5.

If you use csm then you'll be lucky to get 60% resin/glass ratio and get it fully wetted out. If you use woven then you should be able to get it down to 50/50. If you can get hold of some really light triaxial then you can get it down even further.

If you want to play around with a few materials then try using diolen as it's really flexible but you need to use poly resin with that otherwise the elastic modulii are getting close to incompatible. If you use diolen then you can have a little contact without it cracking the laminate.

Don't make it too stiff or thick otherwise you will be fixing it everytime you have contact (plus it's extra weight)

Chris
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