Discussion
I don't know if anyone can help! there is a yellow Saggy racing in Britcar (I'm sure you all know the car), it has a flat floor which is made of a composite aluminum sheet (I know where to get the composite sheet). Whoever undertook the works on the Saggy has made a beautiful job of the flat floor, they have used a type of flush washered fixing to fix the sheet to the chassis, on the off chance someone has looked at this particular flat floor and could tell me what these fixings are it would be much appreciated - long shot I know!
I don't know what Dennis has used on his Racesport car, but on my honeycomb floor I use M6 button head bolts with washers. They don't protrude very far at all.
Where the panel bears a load, i.e. the splitter which is also honeycomb and extends partly under the engine, I use the same M6 button heads, but they pass through top hat inserts which are bonded into the honeycomb with aerospace expoy adhesive. I had the top hats machined so that they are inserted either side of the panel through a 10mm hole, and when the bolt is tightened it applies a small amount of pinch to the panel but will not crush it any further than the predetermined amount. The rest of the floor is not load bearing so doesn't need the same security of fixing. Which is just as well as the top hats were not cheap !
Where the panel bears a load, i.e. the splitter which is also honeycomb and extends partly under the engine, I use the same M6 button heads, but they pass through top hat inserts which are bonded into the honeycomb with aerospace expoy adhesive. I had the top hats machined so that they are inserted either side of the panel through a 10mm hole, and when the bolt is tightened it applies a small amount of pinch to the panel but will not crush it any further than the predetermined amount. The rest of the floor is not load bearing so doesn't need the same security of fixing. Which is just as well as the top hats were not cheap !
Not sure how they have done it. On some of mine I have routed one side then folded the remaining skin over to form a flat finished edge, bonded with PU adhesive. Of course that only woks on a straight edge. It is bloody difficult stuff to finish nicely and I think Dennis must have a special tool or die that he runs round the edges - particularly as he's done it round curves too.
On the leading edge of my splitter I toyed with the idea of routing a slot and bonding in a rubber fillet to take the inevitable whacks. In the end I simply pushed in the core and filled it with black PU, smoothing off the edge. Its flexible so should not fall out when it is hit.
On the leading edge of my splitter I toyed with the idea of routing a slot and bonding in a rubber fillet to take the inevitable whacks. In the end I simply pushed in the core and filled it with black PU, smoothing off the edge. Its flexible so should not fall out when it is hit.
teamHOLDENracing said:
Not sure how they have done it. On some of mine I have routed one side then folded the remaining skin over to form a flat finished edge, bonded with PU adhesive. Of course that only woks on a straight edge. It is bloody difficult stuff to finish nicely and I think Dennis must have a special tool or die that he runs round the edges - particularly as he's done it round curves too.
On the leading edge of my splitter I toyed with the idea of routing a slot and bonding in a rubber fillet to take the inevitable whacks. In the end I simply pushed in the core and filled it with black PU, smoothing off the edge. Its flexible so should not fall out when it is hit.
On the leading edge of my splitter I toyed with the idea of routing a slot and bonding in a rubber fillet to take the inevitable whacks. In the end I simply pushed in the core and filled it with black PU, smoothing off the edge. Its flexible so should not fall out when it is hit.
teamHOLDENracing said:
Not sure how they have done it. On some of mine I have routed one side then folded the remaining skin over to form a flat finished edge, bonded with PU adhesive. Of course that only woks on a straight edge. It is bloody difficult stuff to finish nicely and I think Dennis must have a special tool or die that he runs round the edges - particularly as he's done it round curves too.
On the leading edge of my splitter I toyed with the idea of routing a slot and bonding in a rubber fillet to take the inevitable whacks. In the end I simply pushed in the core and filled it with black PU, smoothing off the edge. Its flexible so should not fall out when it is hit.
Thanks Andy for your help, by the way how is that car of your doing? any pics you can share of the new engine?On the leading edge of my splitter I toyed with the idea of routing a slot and bonding in a rubber fillet to take the inevitable whacks. In the end I simply pushed in the core and filled it with black PU, smoothing off the edge. Its flexible so should not fall out when it is hit.
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