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Oem door panel minus speaker, door Handel and bunch of steel clips weighs 3.2kgs, my door panel weighs .9 kg. Once complete, there will probably be a 2 to 2.3kg difference per side.. it's not much, but 4kgs is still a good amount. (The extra .3 will come from the Alcantara) and it's a project I am enjoying..

Interesting extended weight reduction job !!!

Great thread! Will be most useful for my race car build.

Although I can't say that I recommend using flammable materials (wood and glue) for doorcards

Thanks for the comments Liam,
pretty much ALL door panels are made from flammable materials. (bare ALU being the exception to the rule)

Very true. But not so much on track/race cars (which tend to catch fire more often than road cars). Carbon fibre and ABS plastic being most popular.

No criticism intended - you've done a great job - and the weight saving is impressive.

Thanks again Liam, this is only a hard mould. I have abs plastic panels on its way, but they are also flamible. cF is probably the way to go, but the price is astronomical, for what it is fibreglass is even more flamible than wood. Ask me, I used to shape surfboards. Lol

When are you going to start stripping yours.

Vanne wrote: ↑Wed Jan 23, 2019 12:00 pm When are you going to start stripping yours.

As soon as the current race car is sold! Although I might sneak in a cheeky trip to the 'Ring before starting on the full build

I’m guessing there will be some bits people on here need for sale

Yup, my whole pop up screen, amp, radio, tv media box thing and nav computer/rom bits are all up for grabs.

Lol due to popular demand and some guys pointing my nose at the obvious..


Just bought some 2x2 twill of CF material. specs below.
Going to see if my surfboard shaping skills haven't left me.



Material
High-quality Toray Carbon Fiber
Weave: 2*2 twill
Ends Per Inch :13
Yarn Size: 3K
Thickness: 0.012"/0.3mm
Weight: 7.1oz / 240gsm
Tensile strength:640KSI / 4380Mpa

This should be fun, I wonder what would be nicer, matt or gloss, probably matt id say.

Depending on the cost of the resin, should turn out pretty cheap, even if I have to double up on the CF to get the thickness I need. Looking for 1mm thick skin. hopefully will turn out pretty darn light.. sadly, if it turns out really nice, it would be a shame to cover up the CF with Alcantara, so if this does turn out good, ill probably only cover the arm rest in fabric.


Note: I've decided against using the P-rs3 door pulls as dual action, opening and unlocking the door, as if something happens and gowd-forbid, you need to get out fast, id never forgive myself if something went wrong with the door pull and for whatever reason that you couldn't open the door. Going to use the stock oem door openers.. at least they are engineered to work, and safe.

The door pulls will be just that, a door pull. not for opening and unlocking the door, just to pull the door shut.. because of the way this panel is designed, you could probably use the armrest to pull the door shut..

That's with rollbar, rear and front Stb (back one is heavy) big battery in the boot, (11lbs one on the way) and door cards in place. Lol and full fuel. so half tank would be minus 27.5 kgs.

Note the rear right will come down by 7kgs for the batt, with the fuel at 1/2 tank which will pretty much put it in 50/50.

Pretty darn happy with that.

Looking forwards to an update on your self fabricated cf door cards
Shouldn't have let it slip that you're handy with GRP

No ballast for a driver I presume? That’s pretty good anyway, although you’re over estimating the density of petrol (half a tank weighs less than 20kg).

What are all the electronic boxes on the rear of the firewall? (where all the speakers are located). Do you reckon that firewall adds much torsional rigidity?

What are the stats so far; weight loss to date & performance improvement?