Sub 2500 lbs. 96 Mustang Cobra Project...

[Paul Bird]

In my continuing effort to get my car under 2500 lbs. (wet) I am reproducing all (100%) of my body panels in carbon fiber/nomex honeycomb. So far I have done the roof and trunk lid.

I laid up the trunk lid on Saturday. It turned out great and was actually a little lighter (2 lbs. 9 oz) than I had predicted. Just for reference sake, the stock lid without brakelight, wiring, and insert weighed 26.8 lbs. This makes my piece 90% lighter than stock.

I will be laying up the license plate insert this week. I made it a separate piece so that it will retain the stock look. I also wanted to make it separate so that I can vary the design of the insert - ie a vent panel for the diff cooler, fuel filler, etc. I also thought that someone might just want an insert for their stock trunk for the look. BTW, the insert should weight in at 4-6 oz. which will keep the total weight under 3 lbs. Anyway, here are some pics:

Mold

Lay Up

Finished Part ready to trim


Trunk lid trimmed and on car:


Payoff:


I also laid up a carbon fiber/honeycomb roof a couple weeks ago. It weighs just over 4 lbs. and allowed me to remove 30 lbs. of structure from my roof:

[Insignificant]

Insanity

[93Cobra#2771]

THAT, boys and girls, is very cool...

[Cellos88gt]

That's ****ing awesome!! Where you getting all this carbon fiber from?? Whats going in for motor?? Goodluck man and definately keep us updated cause this is one project I am really interested in!

[1FSTCAT]

Originally Posted by Cellos88gt

Whats going in for motor??

He's got a carbon fiber mold already laid out for the 4.6. If everything comes out correctly, his DOHC should be around 9.5 LBS!!

LOL

Seriously - Cool project!

How much time does it take for you to make a custom panel like that?

--Ed

[tweak302]

WOW, glad to see some real talent going into some REAL work, and not fabricating crap for hondas. This is a killer project, how are you making a mold for the CF? Just plaser around the stock parts??? Are you going to pait it?

good job, and i wish i had your skills/talent/patience/devotion/patience/and patience

[Paul Bird]

Thanks for the props guys. The carbon I am using is standard 5.7 oz. twill that you can get online just about anywhere. The nomex honeycomb is harder to find but is also widely available and VERY expensive.

As for the motor, it is a VTEngines built all forged 9.6:1 shortblock with valve jobbed heads and stock cams and intake. The motor is also wearing Garrett GTBB turbos and a full dry sump system. BTW, this car is a road racing car that is being setup for running NASA American Iron Extreme. Here is a motor pic:

[slowcobra]

Now that is someone with too much time on their hands! (mumbles under breath: bastard, I rarely get jealous of people but this sumbitch has done it)

[93Cobra#2771]

Holy crap, that is beautiful!

[dba-murder]

That is really cool Keep us posted. I'm sure I'm not the only one who thinks this: I see a lot of people wanting to buy your products.

[1FSTCAT]

So, how long does it take to do a panel like that?

--Ed

[DOHCMERC]

Is the bar-b-que carbon fiber???

J/K!!..............That is the kewlest!!!

[Eric G]

You better not paint it. That would look sick.......an all CF mustang.

[blackbuck]

Maybe I've just been out of it but how did you rig up a dry sump? just curious... off the GT? Or is it custom?

Trunk looks nice... going to make doors too?

[Paul Bird]

So, how long does it take to do a panel like that?

Laying up the part in carbon isn't that big a deal. The big deal is prepping the part and making the mold. That takes a LOT OF TIME.

Is the bar-b-que carbon fiber???

Not Yet! but am looking into high temp epoxies though for some other projects.

You better not paint it. That would look sick.......an all CF mustang

My plan right now is to simply clearcoat the entire car which will have a 100% carbon fiber exterior. I know that it will peg the 'Bling Bling' meter but these aren't vinyl stickers or single layer carbon on 1/4" thick fiberglas. These are true lightweight parts on a true race car. With that said, I truly hate rice so it is a bit of a delima. Plus black is HOT.

Trunk looks nice... going to make doors too?

Yep. They should weigh in at around 4.0 lbs. which is a little heavy, but I am going to make the inside laminate of the doors out of balistic Kevlar for safety reasons so it is justified.

[vrtical]

dayum! yeah not painting it will save you like 14lbs

[97--cobra]

That stuff is SICK man. My S 351 could use some weight saving carbon parts.....

Once again, Paul proves that if you got the balls, time and $$ if you dream it, it can be done. I look forward to riding in the 2,500 lbs 500 hp missle.

[87 LX]

Thats is an awesome idea....Any chance you can make a trunk lid for fox coupe

[blackbuck]

Originally Posted by Paul Bird

Yep. They should weigh in at around 4.0 lbs. which is a little heavy, but I am going to make the inside laminate of the doors out of balistic Kevlar for safety reasons so it is justified.

LMAO. 4lbs is heavy? I guess most of the doors is glass weight but they seem to wiegh like 100lbs stock.

Dude make extras!

[Paul Bird]

dayum! yeah not painting it will save you like 14lbs

That is the No. 1 reason I am not painting the car. Sad isn't it.

My S 351 could use some weight saving carbon parts.....

Terry, you used to try to tell me that your car handled better because the extra weigh pushed it down in the corners. Did you change your mind?

Any chance you can make a trunk lid for fox coupe

Maybe, although I don't have one to make a mold from. Hmmm.

I guess most of the doors is glass weight but they seem to wiegh like 100lbs stock.

100 lbs. Probably if not more. My doors with no window, motors, locks, window mechanism, side impact beams, mirrors, interior trim, speakers, or inside sheet metal still weighs 33 lbs each. And this was as far as I could shave it back and still have it shut.

[MustangGT92]

That really is a sweet project.

I think you've got a business in your hands, dont let it slip away.

[The other Austin Phil]

This is incredible!! Good job man!

[nick89302]

Nice job!

[dba-murder]

The more I look at those picts the more I drool. I want to put my turd on a diet like that. After all, if it weighs less it doesn't need to be all powerful. I really wish I had your skill.

[Marlin]

I also think that you have a business in the making.

[bkman4]

Totally awesome. What did you make the molds out of? Thanks man.

[poorracerkid]

WOW! That is the coolest thing that I have seen anyone do to a mustang!
Do you just mold off the stock parts? I have never done carbon but it looks to be not too difficult. Is this your first carbon project or have you done other things is CF?

[90lx351]

hmmmmmm i want your parts lol. ill send you my body parts can you make me some stuff lol

[93FIVEOH]

Originally Posted by poorracerkid

Is this your first carbon project or have you done other things is CF?

I want to know the same thing. Did you practice on small items before tackling big jobs? That's some sweet talent man.

[The Fox Rocks]

See, even when it comes to carbon fiber, we simply do everything better than the ricers.

-The Fox

[NIUPonyBoy]

f'ing sweet dude!

[COBRA90GT]

That just put the SVT/DOHC "Official Weight Removal" thread to shame.

[kim]

PAINT IT!!!! Please, I understand the paint will add weight, but I am SOOOOOO sick of unfinished carbon fiber pannels on Honda's etc......... run in primer... anything but unfinished carbon fiber.

[ANannerup]

Hard not to admire the work you do there. Please keep us updated.

And as others have said, I sure there could be a great business idea out of this.

[Oktavius]

How will that carbon fiber and epoxy hold up with sun exposure? My experience with composites comes from homebuilt aircraft. I know that they all pretty much paint theirs white to help with sun exposure as too much is not a good thing.

This project does look really cool though, especially the roof. I plan to build me a custom hood in the near future. Maybe I will make me a hatch or something.