cmerce

I'm wanting to have a set of carbon fiber doors on my car because my shaved door handles are cracking. I'm totally down for carbon fiber doors to look sweet and shave off some weight. The Seibon carbon doors are running about $1600 which is way overpriced because it looks to me like a carbon skin bonded to a metal door frame. The fiberglass on the back side is low quality chop strand, and I'd bet the resin is cheap polyester.





I'm a composites engineer so I'm just going to make a mold from an extra set of doors I have, and then a set of carbon fiber door skins from the mold. They will be made with carbon fiber, a honeycomb or foam core, and epoxy resin. Then I'll cut out the existing metal door skin and bond the new composite skin with structural epoxy adhesive. The composite skin will be lighter and stronger than the steel it replaces.

They should turn out pretty sweet. What I'm wondering is if anyone would be interested in carbon fiber door skins for half the price of Seibon doors. I can make a mold in the stock configuration if enough people are interested. It's easier for me to make a stock mold now, before filling in the side molding and door handle for my car. Or I could hook it up with shaved carbon door skins for anyone who prefers.

ALLxMOTOR EG

Interesting.

98civdx

hmm, sounds like you know what the hell your doing.
im interested to how they turn out.

danielfleenor

not feeling it.. if u like it go for it!

VI Boost

x2

STOCK_SOHC_DX

If you made an EK version I would be in for this.

K20egcw

Would they still have the option of door moldings as well? Im kinda interested in gettin some carbon doors to save weight but my car is also a DD so im afraid of having my door ripped off if I open it when its windy outside lol. Im not really sure on how the doors are supported to the hinges, if its anything like the hoods then they'll rip out fairly easy.

98civdx

im sure the door will have some sort of frame, made of metal or something like that.
other wise they probuly just brake, after a while.

ej1love

just dont slam em, or have a pms'n ole lady...

98civdx

hahah,
well it would be another reaosn why my girl friend couldnt ride with me, or shell just make you open and close the door,
mine would do that lol

cmgogo

@OP
Hey im down in portland if you need any help. Just a suggestion though, you might want to look into making a frame from boron nitrite. It will cost a bit more, but since your a composites guy, you know how well it will stand up to use. Also if you need help let me know, im an A&P who did alot of composites work while in the navy, and once i got out as well working as a contractor for bell HC, sikorsky, dassault falcon, sino sweriggen, and a few others in their structures departments.

boxeocampeon

let us kno how it turns out

Ruben19

i think it'll look great

K20egcw

Its not me im worried about slammin em. Sometimes my friends slam the door cause they dont think it'll close right lol. Guess if I get the doors, ill have to tell my friends slamming doors = GTFO!!

EG'SUS

Very

cmerce

The plan is to use my existing metal door frame and epoxy the carbon skin on with a structural adhesive. You guys bring up a good point with the door slamming. I think the reason my shaved door handles are cracking is because of the solenoid sending a shock wave through the door near the handle every time I open it. Slamming the door could cause a fatigue issue with the bond line between the carbon and steel. Another issue is the coefficient of thermal expansion of the two different materials. Carbon and steel expand and contract at different rates when the temperature changes. Which also fatigues the bond line.

So I figure I better use the best epoxy adhesive I can get my hands on. Lord Fusor 116 is what I have been using to bond carbon hood skins to hood frames. It is some pretty high tech stuff. It's a cross bonding epoxy designed to be used in bonding carbon-to-metal. It fits in a standard caulking gun and runs about $50 for the tube.

1988_96hb

not my thing but gl.

cmgogo

thatl work as well! Like i said tho, if you need any help with the fabbing let me know. Oh and can you get your hands on any DTME accelerant? Its nasty stuff, but its the best stuff around. Just havnet found anywhere to get it since i got out of the navy. (apparently its registered as an explosive)

cmerce

Thanks I appreciate that, it sounds like you have some good engineering experience under your belt. What is DTME accelerant? I've never heard of it before.

cmgogo

nasty stuff, it will get epoxy resin to set in about 5 minutes, stuff is so exothermic it will melt a hole polycarb in about 30 seconds. Bad thing about is they have to ship a 2oz glass vial of it in a 1gal metal canister that is full of sawdust to keep it from getting bumped around, it is about as stable as nitro.

shietzitzkien

in for the outcome.

ej1love

how much weight does each cf door save anyway?

cmerce

Probable not very much considering just the skin is just swapped for a carbon version. I would guess 4-5 lbs per side.

I'm just down for the cool factor, and I'm trying to see if it's worth making a mold for oem door skins so other people can buy them, or if I should just make shaved versions for my car.

Jimster480

I would totally put carbon fiber doors or a carbon fiber hood on the car but I would paint it so that nobody knows.

skar1

Sounds awesome, subscribed!