Composite Subaru Body Kit

Our first project and the first part put into series production.  The fenders were sculpted by hand and replace the OEM fenders on the car to allow room for wider tires and increased wheel travel.  The parts are made from either low temperature prepreg or wet layup in both carbon and fiberglass.  All parts are vacuum bagged and in the case of the wet layup parts, post cured in an oven.

Semi-Stressed Dry Sump Oil Pan

This project is the first of the trio of parts intended to allow fitment of a Honda K20 engine in a Swift DB5 Sports 2000 race car.  The engine in the Swift DB5 is a semi-stressed chassis member which relies on the dry sump oil pan to relieve the engine block from undue stresses which can distort the block and lead to failure.  The pan was designed and machined in house, starting from a 93lb. billet of 6061T6 aluminum.  The pan includes integral baffling which couples adjacent cylinders together to reduce pumping losses and increase the effectiveness of the scavenge stages of the pump.  The pressure stage of the pump feeds into a passage in the pan which feeds the engine block directly,

Transmission Bellhousing Adapter

This project is the second of the trio of parts including the dry sump oil pan above.  The adapter transmits the load from the engine block and dry sump oil pan to the bellhousing of the transaxle which incorporates the suspension mounts.  the adapter allows the transaxle to be retained and eliminates the need for a bespoke transaxle for the Honda K20.  In addition, the adapter incorporates the mounting points for the relocated starter.  This part was also designed and manufactured completely in house.

Ariel Atom Rear Wing Struts

The wing struts were designed to support an off the shelf composite wing and mount to existing points on the Ariel Atom's tube frame.  The struts allow for adjustment of the angle of attack through a series of mounting positions.  To improve the aerodynamic performance, the leading edges were rounded and the trailing edges were tapered.  The struts were machined from 6061T6 plate, milled in house.

Carbon Fiber SSD Enclosure

A prototype SSD (Solid State Drive) enclosure was designed and produced, taking advantage of the properties of carbon fiber.  In contrast to a standard aluminum enclosure, the only restrictions on the thickness of the enclosure walls are structural and not limited by machining or casting technology.  That allows for much thinner walls and more storage space inside the enclosure as the outer dimensions are limited by international standards.  In addition to the capacity increase, the inherent RFI shielding of carbon fibers makes the drive well suited to harsh environments and military applications.  Further testing on RFI and EMI shielding of the enclosures and hybrid composites is warranted.