splitter materials

Gavin

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looking for lightweight material to build splitter -Carbon Firber is not an option.
Plywood too heavy and ugly
Any ideas or sources?
Was wondering what the Nascar boys are using on their OT cars
 
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Gavin

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No good - can buy aluminum w/cored center - bends too easily - need a materila that can handle normal track type impacts and not shatter or bend - looking for composite type product
 

2000_Black_RT10

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You can get aluminum sheet in different grades and tempers. If you're seeking a composite to survive collisions you're not going to find it, it would not be the choice of material. Aluminum is the way to go as suggested.
 

2000_Black_RT10

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Here is a link to a fabulous product called "starboard". It is a full color solid core plastic material used to make swim platforms on boats. It is machineable, self supporting, comes in different thicknesses and colors. I believe it will suit you just fine.

http://www.kingstarboard.com/Products/_StarboardFamily.aspx

Good Luck.

Sorry, not to be jerky.. I reviewed the material characteristics / physical properties on their site, it is similar to HDPE / high density polyurethane (i.e. bedliners, plastic fuel tank material). The yield tensile strength is quite low at 4100 psi and it would have to be quite thick to support the downforce. Aluminum (i.e. 6061) can range from 14,000 to 38,000 psi depending on the temper (treatment). Carbon fiber is widely used which typically weighs 1/2 less than aluminum of equal strength requirements. I wouldn't recommend the polymer sheet material for a splitter, to match the strength of low grade aluminum it would have to be 3 - 4 times thicker than aluminum, so it will be heavy and thick.

As a suggestion of a material to sustain impacts, sure it could be used, but not as a functional / efficient splitter, especially at high speed. The starboard material is good for flexing which is something to avoid for a splitter. If the splitter angle changes then there will be more downforce, not good, splitter may fold under the car.. I would guesstimate the starboard polymer sheet would have to be 1" thick, otherwise it would flex significantly (such as 1/2" or 1/4" thick). If the thickness is not a parameter in the application, try it out, considering weight / density starboard is approximately 0.024 lb/in3 whereas aluminum is 0.098 in/in3 (heavier). Sure steel is an option also, higher tensile strength is available, yet more density / weight..

In the end of all this babbling, regarding all the aspects including cost and replacement, you can't beat aluminum if it's going to be beat up at the track.
 
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CANTDRIVE55

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I would agree with Chuck....inexpensive and easily replaceable if broken. I agree that Starboard would end up too bulky for the application.
 

steve911

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On a gen 3 car, the amount of unsupported material is not that large. with the front splitter cables coming from the core support down to the front of the splitter and the mounting pattern on the chassis itself flexion is pretty nil. The tensile strength of the product is immaterial as you are not pulling on it as you would a rope to try and break it.

The material was designed to be used as a swim platform on boats. It has good compressive strength and is pretty self supporting as I am sure everyone has seen that swim platforms are not overly braced. I will grant you that the usual thickness approaches .750 of an inch, but then again you might have a half a dozen people sitting or standing on it depending on size.

How much weight is exerted on a front splitter AT SPEED? Take into account also how much splitter actually sticks out to catch the air compared to a swim platform. You can definitely go thinner.

My take on this whole subject is the original author was looking for a low cost alternative to make a functional splitter. I agree whole heartedly that anything that one could buy at a Lowes, Menards, or Home Depot would be unsuitable.

As an USAF Aircraft Structures Specialist for the past 35 years, even aluminum has its draw backs. 6061 temper which is readily available in the non aircraft commercial market is still quite malleable even at the T6 temper. In order to gain strength one has to go thicker approaching 1/8 in thick or more. 2024 series, is more rigid give equal thicknesses than 6061 but it is much more expensive. An any impact to the aluminum will bend it and it will be difficult to get it back into shape to look good cosmetically.

I did not get the impression that this was going to be an all out race car. If I am correct, weight isnt going to be that critical. Get something that will absorb some of damage and keep its shape.

NEXT?
 

CANTDRIVE55

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I agree that Starboard is tough stuff and I've used it on ADRENALINE and other boats in the past. Perhaps if the leading edge is milled down from the starting 1/4" thickness, this could be good stuff. In any event it seems that no matter what material employed you'd best accept the reality of having to replace it (and collateral damage) sometime.
 

2000_Black_RT10

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On a gen 3 car, the amount of unsupported material is not that large. with the front splitter cables coming from the core support down to the front of the splitter and the mounting pattern on the chassis itself flexion is pretty nil. The tensile strength of the product is immaterial as you are not pulling on it as you would a rope to try and break it.

I'm not here to debate, just some friendly conversation. The splitter cables don't see a significant load because the carbon fiber splitter is flat and rigid, it's in a horizontal neutral zone, limited surface wind force upward or downward and no airfoil effects. The function of the cables / links is to make sure the splitter doesn't change angle which would be significant forces at high speed affecting the vehicle dynamics, unlike support for a front / rear wing providing downforce.

If the splitter shape distorts along any part of the surface (due to bumps at high speed, sag if the starboard material was too thin, thermal material property change sagging the ploymer, etc..), resulting with downward wind force. Typically there are only 2 cables on a carbon fiber splitter, because the carbon fiber splitter is very rigid. On something weaker like thin aluminum sheet, it may require multiple cables or gussets / ribs to maintain a flat surface, due to material deflection. This is the only reason of emphasis for rigid material. As long as the starboard material is thick enough and supported, shouldn't be a problem as a cost effective solution to withstand bumping. I would just buy a 4x8 sheet of aluminum, make a template, fab up some riveted angle section supports on the underside. If it'***** beyond repair, just cut a new splitter from the template and replace the rivets, etc..

Have fun.. sorry for the long replies in your post Gavin.

Surely Chuck's suggestion of fibreglass would work too.. dave6666 - do you have a link to the manufacturer of this unobtanium? :dunno:
 
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