This type of mould has been 6 months in planning here at HT Autos and so far hes taken us a month to 'nearly' complete top half of spoiler.
Benifits of this system, is that we will be able to produce a spoiler far more superior to any GRP/FRP (fibreglass) replica's out there.

This system is the same that PRODRIVE used to manufacture all the production P1 spoilers and this project is being supervised by BRIAN GRAHAM ( the man who made the mould and all the original P1 spoilers).
It works using Polyurethane foam, which in a reacted state will expand about 30 times in volume, but with the help of 10 ton of pressure ,we will only let it expand less than twice, which will form about 2mm of rock hard plastic skin and a very dense urethane core, which is lightweight and extremely tough.

Pics so far ,below.......


Tooling on stand at angle of 15 degrees..





2.5 Ton toggle clamps...




Specially made adjustable hinges...





2500 newton rams...




There is more urethane in model than foam block....





This pic shows strength on 1mm section...




Hope this is of some interest to some of you?

Cheers for looking!

Mark @ HT Autos

 

looks good Mark , we need a decent v8 spoiler

 

Interesting stuff, how long does it take to fully harden?

 

Very interesting. Keep it coming

 

Can be varied, BMW use the same sytem to make thier spoilers with a 7 second cure time, but the machinery to get that much material in costs millions ££

Mark

 

any other versions planned????

 

We will probably do the version 6 early next year

 

Interesting read

 

Started work on base of spoiler today


Masking tape is used to mark out split line......



Wooding out process started..........



Mark

 

Awesome ! as always top work Mark

H

 

Got a bit more 'wooding out' done today

Now going to watch some fireworks with the kids








Mark

 

Got a sample of the material being used and machinery coming next week, so fingers crossed should be having a part from the 1st mould soon

Mark

 

Could be interested at a good price

 

Price will be about £200 or less

 

Managed to get 'T'bars and locators in place today.
Also started to box out






Mark

 

hmm interesting stuff! Keep it coming. (v6 splitter )

 

Bit more done today....


Finished boxing out........


Inlet feed in place......


Coat of High Temperature Epoxy Gelcoat to base.........


After 1st coat has dried to tack, second coat applied and also up sides....


When this has tacked off, 3 layers of multidirectional glass tape is applied with high temp epoxy resin.....






Mark

 

Next a 15mm layer of thermal conductive Epoxy Paste Laminate.....



9 hours later


Mark

 

Time to put in some Central Heating
Mould must run at 30'C


Made up some end baffles.....



Soldered and put in place.....




Mark.

 

Pipework is buried in another layer of Paste Laminate.......





Next, hardware is put into place, which will support hinges, clamps ETC.







Then a mixture of Epoxy Resin, Binders, Chopped Fibres and sand is used to top up!.........







Mark

 

Blimey, I bet that weighs a bit!

 

Tooling (mould) for complete spoiler will weigh over 1 Ton

Mark

 

don't drop it on your foot!

 

 

Turned 1st half over today and removed wood........





Boxed out other side........




Mark

 

This certainly puts into perspective the amount of work put in to produce a qulaity piece.

Keep up the good work guys

 

So am I right in thinking that you'll have to do this all over again for the top half of the spoiler?

ETA: I've just woken up and re-read the first post

 

Great work fellas

 

This is where we are up to so far with lid..............











Mark

 

Got hinges and brackets welded on today.
And cracked open the mould....





Mark