SCCA FB rules require a metallic or composite front impact attenuator. Can’t have cars running around on the track with a battering ram on the front… My impact attenuation structure, or crash box, consists of a carbon-fiber and honeycomb sandwich laid up directly on the inside of the fiberglass nose. The carbon fiber varies from four layers at the front to eight layers around the rear attachment points so that it will crush progressively from the front to the back. Cylindrical aluminum inserts are used in the honeycomb as hard mounting points for the wing to the nose and for the nose to the chassis. This area is designed to be strong enough not just to absorb impacts but to allow lifting the front of the car by the front wing.
- Aluminum mounting points are first epoxied in place with the nose on the frame
- Inside view of gluing the mounting points in place
- Hard mounting points after epoxy has cured
- Cutting the vacuum bag to approximate shape before duct-taping it
- Using template to cut carbon fiber
- Aluminum inserts in side honeycomb pieces create hard points for mounting
- All the layers ready for layup
- Beginning the layup by coating the existing nose with a layer of epoxy
- First piece of carbon fibe goes in.
- A honeycomb and aluminum assembly is inserted on the side
- Ready to draw a vacuum
- Good vacuum after taping over microscopic holes.
- Removing the breather cloth
- Removing the perf ply
- After all vacuum-bagging materials are removed