What is this material?

[Robb F]

I'm in the process of restoring / modifying an R32 skyline. Part of the build is to cut out the spare wheel well and replace with a fuel cell. I'd like to make a false floor above this to hide the top of the cell and the pipework etc.

I could use plywood, but it feels like a bodge and it's heavy. I'd quite like to use the same sheet material OEMs use for this. Obviously it varies slightly by manufacturer, but it seems to be some sort pressed recycled plastic fibre.

The problem I have is I have no idea who, if anyone, sells it, or even what it's called to be able to search properly for it.

So is any one in know of how to find this stuff? Pictures below for reference. (I'm not expecting to buy it trimmed already)





The pictures may be ambiguous, the above items go on the boot floor, they’re not parcel shelves.

Edited by Robb F on Thursday 28th September 22:20

[Scrump]

I know it as automotive fibreboard. A Google of that term brings up a few hits, the first one being this:
https://www.segalmotortrimmings.net/index.php/foam...
Seems it is may also be compressed card!

[tapkaJohnD]

Rob,
You say that plywood "is too heavy". So I assume that this panel is very light! But also very stiff, if it protects the top of the original fuel tank. And, the back view looks as if it has two thin surface layers, separated by a honeycomb. Such construction is of course famous in F1 and other circles, but carbon fibre requires autoclaves and other costly kit, so probably not an option for this.

But glass fibre can make very light panels with the same technology, using paper honeycomb between two thin panels. I did this to make a car roof, and achieved a result that was a quarter the weight an d a hundred times stiffer in this way. I used a much larger cell size honeycomb than I can see in your pics, but worth a try? You can get paper honeycomb on ebay, EG https://www.ebay.co.uk/itm/334923894764?hash=item4...

Good luck!
John

[Bill]

You can also get lightweight plywood as used in campervans.

[GreenV8S]

tapkaJohnD said:

carbon fibre requires autoclaves and other costly kit, so probably not an option for this.

Pre-preg carbon fiber usually does, but you can also vacuum infuse with relatively cheap equipment, or simply wet lay up in the same way you would for fiberglass.

[Novexx]

Wisa-Spruce (ply) is pretty strong & light.

[Robb F]

Scrump said:

I know it as automotive fibreboard. A Google of that term brings up a few hits, the first one being this:
https://www.segalmotortrimmings.net/index.php/foam...
Seems it is may also be compressed card!

Thanks

This seems to be different stuff though as it’s only 2mm and “non structural”.
The stuff used in typical boots is between 10-20mm thick from memory, and can comfortably take my weight when hoovering back there

[Robb F]

tapkaJohnD said:

Usefull stuff

It is indeed, it’s remarkably sturdy for the weight in fact.

I’ve looked into using composite sandwich sheets but I mostly abandoned the idea as it’s very expensive and the design of them means it’s not possible to put a radius on the edges, which I think will look a lot neater (I know I’m being fussy)

[Robb F]

Bill said:

You can also get lightweight plywood as used in campervans.

Thanks, I didn’t know this existed, looks perfect.

Current front runner if I don’t manage to track down the OEM stuff

[Robb F]

Novexx said:

Wisa-Spruce (ply) is pretty strong & light.

Thanks, I’ll take a look

[GreenV8S]

Honeycomb composite seems massive overkill if you just want a cover.

Either a sheet of aluminium or fiberboard, covered with a skin of fiberglass if you want to be fussy, seems more than sufficient.