hey hey hey.........thank you for showing the thin application of fibergless BEFORE putting the kevlar in the mold part..... with this application with the fiberglass before the kevlar....... it covers the worry of sun baked kevlar ......
I used to be a fibreglass laminator many moons ago, and a wee tip I picked up was screw pattern rollers are better than paddle or finned rollers, they cost about the same, not bad rollers so they are.
In Russia, in areas with humid climates, foam in the rapids will lead to rapid and inevitable corrosion. In 80 and 90 years of the last century, Ford filled the cavity in the body of their cars with foam, as a result of the car rotted for 2-3 years of operation. But the door you have turned out just gorgeous, plastic foam and corrosion is not terrible.
Looks amazing. I finally stuck filler to my mold. Just need to clean it up a bit more and figure out how much carbonfiber I will need to make this happen. Cant wait to see the car done.
Yes I'll show that. Basically cut a slot for the lock to slide in, then dig out clearance for the lock rods. If I put the locs in the door before foaming I risked that one tiny bit of foam getting past any sealing tape, so I decided on the fit later & burrow method instead.
You are not allowed composite front doors in the WRC and in the UK you can’t have any unless they are the rears and homologated but there is only Citroen with any anyway and they don’t need anything in them.. the foam comes in blocks and a CNC is used to shape it.
Actually most expanding foams have fire retardant in them these days. Building authorities would hardly allow it's use as spray wall & roof insulation in modern homes if it was a fire hazard. I don't know what the FIA foam requirements are, but you can guarantee fire retardent is part of the required mix. What is far more flammable is the nylon/aluminium sheet sandwich material (building cladding) that many race car builders (especially clubmans), commonly make their floors & sides out of. Yet no scrutineers seem to worry about it. They see the metal on the outside and forget about what happened in those UK tower complex fires. Exact same stuff. A fire needs an ignition point, which is why I don't use expanding foam anywhere past my windscreen. I can't see how a fire would start inside a foam filled door under normal race conditions. Then there's the flammability of ALL poly & epoxy resins as used in CF and fiberglass. They burn well too, but once again you have to have an ignition point. If a race car burns rapidly it's usually because petrol is involved - and as we know that is explosive.
So if I wanted to make carbon fiber door for my street truck should I make them fully out of carbon Kevlar so it can absorb the impact Incase of a crash?
Carbon shatters on impact, whereas Kevlar is tear resistant, but you might want to to check your local road rules too. However your main challenge for a road car will be mounting all the window winder mechanism and tracks so your windows still work, as fixed windows are obvious to cops and illegal everywhere.
Please rename the title s of the video so that other people can find them...i believe you would have thousands more views if the video would be carbon / Kevlar door tutorial. I can't ever find the video im looking for ànd im subscribed to your channel lol , great videos ..but youtube search is not kind when looking for a particular video
Would it be a good idea to back a thin aluminum firewall with kevlar? What about the inside of a removable transmission tunnel? If yes would polyester resin used with Kevlar be ok?
Firewalls have to be fire resistant, and both epoxy & polyester resins are all flammable. So firewalls can only be made out of metal. But I see no problems with what you are thinking of using for a transmission tunnel, because that is fragmentation protection more than fire proofing. However I'd lay the Kevlar on the top of the tunnel to get the poly resin away from the exhaust heat.
Great video. Love the quality control (qc) at the end, ha. So, what kind of gelcoat did you use, polyester or epoxy? I noticed using epoxy with chopped strand is that great. Its a little difficult and leaves a lot of air bubbles.
I just used poly Gelcoat. Yes, csm with epoxy isn't great. Ended up with a mega hairy finish, so I laid carbon over it after filming to get a reasonable surface inside the door window frame - which you can see at the end of the vid.
Ok. I have mixed polyester gel coats and epoxy resins before. Just not to crazy about doing that to be honest. I feel like the two resins don't really mix well. You could of used some fiberglass/carbon fiber/Kevlar surfacing veil on the top layer for the hairy finish. Thanks for getting back to me. Love the videos.
You can buy special CSM for epoxy , its powder binder. Normal CSM needs styrene in the resin to break it up, epoxy doesn't have this. If you're from Australia, Trojan Faberge stocks powder binder CSM and its cheap! Their epoxy is half the price of west system too
What is the benefit of using kevlar over carbon fiber raisin? I thought kevlar was popular with abrasive places like under body of the car. Could you please shed light on what carbon fiber, kevlar and fiber glass all are meant for and their pros and cons. Please. Thank you..
I can't recall overlaying CF with Kevlar, but it would be done to add the tear resistance of that yellow cloth over CF - which tears, cracks & shatters with impact. In race car use.... Fiberglass: Cheapest, easy DIY, no vacuum bagging needed, Kevlar: Highest tear and abrasive resistance, not as expensive as CF, Carbon Fiber: Lightest and strongest for thickness even when really thin, but mostly needs vacuum bagging to get that & to conform to compound curves.
@@BillsBuildandRace Not overlaying , i am sorry i wrote that in a confusing manner. I was just wondering what material is better for what kind of application. What i mean is why would you make a door of kevlar and not carbon fiber. I find you very knowledgeable so I thought i would ask you pros and cons of all 3 materials. I guess fiber glass is the cheapest and has the most flex. And then carbon fiber is the stiffest with least flex. But I am sure you know more and it would great to hear your input on these 3 materials and their applications. The reason why i ask is because I would have thought doors would be better with carbon fiber , rather than kevlar... no?
@@Jimboyrulez I made my passenger door from CF for maximum light weight. But with my driver's door I wanted the way better protection Kevlar offers in a side impact crash - so that's why I used it there. I also wanted to demonstrate how a much tougher door could be made using Kevlar, as this is what the WRC and our National Rally rules requires, and no-one had shown the DIY race car builders how to do this.
hey hey hey.........thank you for showing the thin application of fibergless BEFORE putting the kevlar in the mold part..... with this application with the fiberglass before the kevlar....... it covers the worry of sun baked kevlar ......
Bill you got yer self a Bulletproof Racecar. Great Work.
Yeah. Might make doors for low riders eh?
I used to be a fibreglass laminator many moons ago, and a wee tip I picked up was screw pattern rollers are better than paddle or finned rollers, they cost about the same, not bad rollers so they are.
That door had zero flex...amazing work!
Another great video 💪🏻 I made carbon Kevlar overfenders for my drift car and carbon Kevlar sills for my rally car all from watching ur videos 🤘😊
Eggs are lent!
You sir, are an international treasure. Thanks from the USA for another great video.
Wish i had these doors with the neighbours i have.great work as usual!
I love the use of The Italian job movie.
Top work Bill, the videos get more informative and professional by the week👍🏻👍🏻👍🏻👍🏻
I suddenly do not feel safe in my car. Lol. Great video! Thanks
Another awesome video.
Been waiting for this one for a while now. Mind blowing to see the impact test at the end. Great stuff Bill!
those intrusion bars are ideal thought for my doorskins.! neat!
Nice this video deserve 1mill view at least
Always love the destruction tests.
Love watching your videos man you really know your stuff
Another great video! I’ll go to the shed and try some more stuff now :D
Always great vids
outstanding vid,,,great knowledge of product,,,you are a winner on and off the track!!
Love your videos, I've learned a lot!
Great video and thank you!
Brilliant video 👌 great instruction. Thank you
Very impressive, you're da man bill
In Russia, in areas with humid climates, foam in the rapids will lead to rapid and inevitable corrosion. In 80 and 90 years of the last century, Ford filled the cavity in the body of their cars with foam, as a result of the car rotted for 2-3 years of operation. But the door you have turned out just gorgeous, plastic foam and corrosion is not terrible.
Nice work bill.
You are the man!
Looks amazing. I finally stuck filler to my mold. Just need to clean it up a bit more and figure out how much carbonfiber I will need to make this happen. Cant wait to see the car done.
You are an awesome guy👍🏻
Great vid
I love you grandpa
Nice video Bill.very informative . will the door resist bullets ?
Wondering if you have a DVD series? I would love to buy it.
Nice work as always. I'm curious to see how you get the door lock mechanism in the door now though
Yes I'll show that. Basically cut a slot for the lock to slide in, then dig out clearance for the lock rods. If I put the locs in the door before foaming I risked that one tiny bit of foam getting past any sealing tape, so I decided on the fit later & burrow method instead.
You are not allowed composite front doors in the WRC and in the UK you can’t have any unless they are the rears and homologated but there is only Citroen with any anyway and they don’t need anything in them.. the foam comes in blocks and a CNC is used to shape it.
Brilliant mate !! So it State of Bill's Art !! Haha !! Seeya Rob
Does the FIA mix have a fire retardant?
Most expanding foams are really flammable, and make a horrible smelling black smoke
Actually most expanding foams have fire retardant in them these days. Building authorities would hardly allow it's use as spray wall & roof insulation in modern homes if it was a fire hazard. I don't know what the FIA foam requirements are, but you can guarantee fire retardent is part of the required mix. What is far more flammable is the nylon/aluminium sheet sandwich material (building cladding) that many race car builders (especially clubmans), commonly make their floors & sides out of. Yet no scrutineers seem to worry about it. They see the metal on the outside and forget about what happened in those UK tower complex fires. Exact same stuff. A fire needs an ignition point, which is why I don't use expanding foam anywhere past my windscreen. I can't see how a fire would start inside a foam filled door under normal race conditions. Then there's the flammability of ALL poly & epoxy resins as used in CF and fiberglass. They burn well too, but once again you have to have an ignition point. If a race car burns rapidly it's usually because petrol is involved - and as we know that is explosive.
So if I wanted to make carbon fiber door for my street truck should I make them fully out of carbon Kevlar so it can absorb the impact Incase of a crash?
Carbon shatters on impact, whereas Kevlar is tear resistant, but you might want to to check your local road rules too. However your main challenge for a road car will be mounting all the window winder mechanism and tracks so your windows still work, as fixed windows are obvious to cops and illegal everywhere.
Please rename the title s of the video so that other people can find them...i believe you would have thousands more views if the video would be carbon / Kevlar door tutorial. I can't ever find the video im looking for ànd im subscribed to your channel lol , great videos ..but youtube search is not kind when looking for a particular video
Would it be a good idea to back a thin aluminum firewall with kevlar? What about the inside of a removable transmission tunnel? If yes would polyester resin used with Kevlar be ok?
Firewalls have to be fire resistant, and both epoxy & polyester resins are all flammable. So firewalls can only be made out of metal. But I see no problems with what you are thinking of using for a transmission tunnel, because that is fragmentation protection more than fire proofing. However I'd lay the Kevlar on the top of the tunnel to get the poly resin away from the exhaust heat.
What resin type used?
I wonder why car manufacturers dont use more fiberglass and other composites in their cars. Hmmm. Love your vids.
Harry Paul Garcia they do corvette is a prime example
Great video. Love the quality control (qc) at the end, ha. So, what kind of gelcoat did you use, polyester or epoxy? I noticed using epoxy with chopped strand is that great. Its a little difficult and leaves a lot of air bubbles.
I just used poly Gelcoat. Yes, csm with epoxy isn't great. Ended up with a mega hairy finish, so I laid carbon over it after filming to get a reasonable surface inside the door window frame - which you can see at the end of the vid.
Ok. I have mixed polyester gel coats and epoxy resins before. Just not to crazy about doing that to be honest. I feel like the two resins don't really mix well. You could of used some fiberglass/carbon fiber/Kevlar surfacing veil on the top layer for the hairy finish. Thanks for getting back to me. Love the videos.
You can buy special CSM for epoxy , its powder binder. Normal CSM needs styrene in the resin to break it up, epoxy doesn't have this. If you're from Australia, Trojan Faberge stocks powder binder CSM and its cheap! Their epoxy is half the price of west system too
Wish I can come over and be your lacky!
i dont see that would be to FIA specs, just due to the fact its resin rich but good detailed video all the same
What is the benefit of using kevlar over carbon fiber raisin? I thought kevlar was popular with abrasive places like under body of the car. Could you please shed light on what carbon fiber, kevlar and fiber glass all are meant for and their pros and cons. Please. Thank you..
I can't recall overlaying CF with Kevlar, but it would be done to add the tear resistance of that yellow cloth over CF - which tears, cracks & shatters with impact. In race car use.... Fiberglass: Cheapest, easy DIY, no vacuum bagging needed, Kevlar: Highest tear and abrasive resistance, not as expensive as CF, Carbon Fiber: Lightest and strongest for thickness even when really thin, but mostly needs vacuum bagging to get that & to conform to compound curves.
@@BillsBuildandRace Not overlaying , i am sorry i wrote that in a confusing manner. I was just wondering what material is better for what kind of application. What i mean is why would you make a door of kevlar and not carbon fiber. I find you very knowledgeable so I thought i would ask you pros and cons of all 3 materials. I guess fiber glass is the cheapest and has the most flex. And then carbon fiber is the stiffest with least flex. But I am sure you know more and it would great to hear your input on these 3 materials and their applications. The reason why i ask is because I would have thought doors would be better with carbon fiber , rather than kevlar... no?
@@Jimboyrulez I made my passenger door from CF for maximum light weight. But with my driver's door I wanted the way better protection Kevlar offers in a side impact crash - so that's why I used it there. I also wanted to demonstrate how a much tougher door could be made using Kevlar, as this is what the WRC and our National Rally rules requires, and no-one had shown the DIY race car builders how to do this.
@@BillsBuildandRace Thank you for the insight... I love your videos... they are very very informative
Any plans to sell copies Bill?
I take it that it weighs not much!?!
15:48 ?
Better than Tesla lol.