RESIN-LAMINATING BODIES

For the Open class and the ultimate in modelcar racing, using bodies either commercially
available from the likes of Fujimi, Tamiya, Revell or Carrera, the FIA GT cars are the pinnacle
of GT Car racing. Raced in the USA under the ALMS Series, in Europe under the FIA GT
banner, at Le Mans, and in the LMES Endurance series, these cars are without a question,
the most awesome looking cars in Global Motorsport.
As raced at the IMCA World Championships, both the FIA GT Cars and the Super GT (JGTC)
series cars are hard, plastic bodies which weigh in around 200 grams, and not only look the
part, but are also huge fun to drive. While they aren't as fast as our current historic Classic
cars, they do provide you with a very high level of realism, and the racing is very close.

One of the main problems with the hobby in general, is the long delay before a manufacturer
releases a new, or relatively current racing car. We sometimes wait over three years for a
Manufacturer to release a car we like, but by then, it's already been superceede3d by the next
best machine on the track. ( Ninco's recent release of the Ferrari 360 Modena's is a prime
example of this), however, both SCX and Scalextric have released the newer, and more
current Ferrari F430 GT cars...

With our entry's in the IMCA series, and the EEC series for 2008, we were assigned cars
which are currently not commercially available as 1/24 scale kits, and so, as has become a
very highly skilled part of the hobby, we've had to join the likes of Belgium and Holland in
replicating current cars by hand, using Resin and Carbon Fibre laminating projects to produce
the car required in competition.

The process is very time-consuming, but will reward the modeller with a very current, and up-
to-date model car, which is seen on the tracks competitive at the top level. Both myself and
the Durban guys, Craig Strydom and Erlo have been assigned "un-available" bodies for the
2008 IMCA Worlds, and EEC Endurance series. I've got the Motorola Ferrari 430 GT, and
Craig and Erlo, the Ebi Motors Porsche 997 GT3. Neither of these are available in current,
updated race trip, and so, we had to resort to re-moulding what we had, to get it race spec.
Below are some Pics, and the process of having to "convert" the road-going model to the
Race-ready version.

First, the standard version, the basic body, which naturally does not have any ground effects,
wings etc. The body requires a lower sill all around, as well as the nose to be rebuilt.
Here, using White Polystyrene sheeting, the Sills are glued/resined in place.

Here, the nose needs to be closed up, and the extended diffuser glued/fitted all the way round
the nose.
Now, you can clearly see the Racing lines emerging.

The Body is looking much more like the track version, and from here, it's much sanding,
preparation, and making sure the car is symmetrical and correct.
The 2007 car has some new cooling vents in the bonnet, and a NACA type duct up the
bonnet. More modelling to be done. Eventually, when you're 100% happy with the finished
result, it's then moulded with a 2 Part Silicone, which we're getting from AMT Composites
here in South Africa. Remember, the Silicone will completely submerge the body, so all open
cavities, like Windows, lights, and wheel arches etc need to be sealed up. Once the Silicone
is cured, it's easily flexible, and the original body can be taken out the mould, leaving a
perfect body replica in the cavity of the mould.
Here you can see the lines of the body in the Silicone mould. This is now ready to be
laminated and resined using a mixture of thin fibreglass matting and Carbon Fibre Strands
with a 2-part resin system. (The following Pictures courtesy of Tamar Nelwan and Team RFH
in Holland.)
Here, the first part is to start with a gelcoat, the smooth outside finish the body will have. This
is painted inside the mould, and worked at for at least half an hour, until it starts to get tacky,
like sticky tape. Then, you start laying in small Fibreglass "mats", for strength.
Again, when tacky to the touch, you then add some strands of Carbon Fibre, which gives the
body its overall impact strength. This is VERY messy, and requires lots of patience, cleaning
materials, surgeon’s gloves etc, and takes about an hour to 2 hours in total. After left for the
correct curing time of the resin, usually around 3 to 4 hours, you can then pull out the body
from the mould.
Here you can see the strands of Carbon inside the resin. This body weighs around 25 grams,
and is extremely light, and once the windows have been dremelled out and all the excess
fibreglass cut away, you're left with a replica of the current body, which then requires some
fine cleaning up with sand paper, some primer, and then colour and decals. The Windows,
lights, interior are then made using the Vac Forming Technique as explained in another topic
on the site.

Article by Alan C Paterson www.slotcars.co.za

Used with the authors permission – John H Green

Completed resin-laminated body, painted and decaled on its chassis.