Full Carbon Bonnet

[Anthony Ball]

After nearly 12 months in the making I have finally today fitted my full carbon fibre bonnet , full double skin utilising all original hardware , fixing points , hinges etc
I’m really pleased with the end result , fit and finish etc but there has been lots of swearing and cursing and head scratching along the way !!
I bought a brand new VW bonnet and made the moulds from this ( it was then sold for same as I paid for it ) and the Bonnet was laid up using resin infusion method , inner and outer skins are 100% carbon and bonded together so the finished article is identical to the original

 

[Anthony Ball]

Some pics of the moulds and process

 

[Anthony Ball]

And the same idea last year on my Mk1 GTE

 

[Loz]

Lovely job...

 

[Fish]

Fan-bloody tastic.. well done mate.. looks mint!.

 

[Ann3x]

wow. Impressive.

 

[Pauly]

Indeed very impressive, thats quite an undertaking to produce one bonnet !

 

[Dellmassive]

nice =]

 

[Fish]

Indeed very impressive, thats quite an undertaking to produce one bonnet !

Might not be one.. @Anthony Ball

 

[Oldrat]

Lovely job.

This man is dedicated to his van, and is single and no kids I reckon

 

[Anthony Ball]

Lovely job.

This man is dedicated to his van, and is single and no kids I reckon

Mrs Ball is very pleased it’s finished , and the kids are quite impressed as well !!
Tbh it was a daft thing to start , but once I’d started I couldn’t stop if you know what I mean, it’s just been odd hours here and there but it all adds up , I reckon probs about 30 hrs work in the mould and I lost count on the actual bonnet , but around 60 I would think , valuable time that has stopped me working on my GTE which is my main hobby , but I’m super happy with the results , I’m toying with having the bonnet/wing joint sprayed blue to match the van and fading in to full carbon around the swage line area ?? Thoughts ??

 

[Fish]

You'd want some super grip fill to hold in it suitue.

 

[zombie_T6]

Did you use a UV resistant resin with the wet layup?

 

[Anthony Ball]

Yes all proper UV resistant resin , also clear coated which should help , the bonnet on my GTE has been done over a year and is not showing any signs of fading or deterioration , although admittedly it doesn’t get used everyday

 

[Scruffy]

Very impressive, but how would it stand up in a front on collision? I know CF is very tough, but as its part of the crumple zone, would it have a negative ( or positive) impact on the vans ability to absorb a collision.

 

[andys]

I thought the crumple zone was just the structural elements of the body?

 

[zombie_T6]

It would just splinter, the checker board is mainly used as a light weight body ply. The twill stripe parts would be stronger at the edges especially if there in a 0/90 lay up.

 

[Scruffy]

It would just splinter, the checker board is mainly used as a light weight body ply. The twill stripe parts would be stronger at the edges especially if there in a 0/90 lay up.

Ok, so is that a good or a bad thing?

 

[zombie_T6]

That depends on how you look at it I guess.

 

[Anthony Ball]

The top skin is 4 layers of 2\2 twill weave ( 2x 200gsm and 2x 600gsm) with the light weight spread tow on top in the centre just for looks the skin is approx 1.5mm thick , the inner is 3 layers of twill , really don’t think it will affect the crumple zone tbh , there are plenty of other cars out there with carbon bonnets so I’m not too bothered