Materials and Manufacturing

With the experience gained competing in rallys and the feedback Rallytech receives from our customers, we are constantly improving and producing new parts, to offer not only lighter weight components, but also better protecting and longer lasting replacements.

With Rallytech’s knowledge and experience of working with different composite materials, Rallytech are able to offer parts manufactured from Glass Fibre, Carbon Fibre, Kevlar and also Twintex.

Carbon Fibre

Carbon Fibre components from Rallytech are available in two forms, Pre-impregnated (Pre-Preg) or Wet lay-up. The basic structure of both forms is the same - the fabric is produced from fine fibres mostly composed of carbon atoms, which are woven into a fabric mat and can then be easily formed to follow the curvatures of the required moulds.

Using the wet lay-up technique, the fabric mat is applied to the mould,  then the resin is applied by a technician according to the requirements and the strength required for the outlined component.

Pre-preg is different in that the mat is sold with the resin already applied. It is required to be kept chilled and once the mat has been formed to the required mould, the component and mould are then vacuum bagged and heated within an oven to the required temperature. The resin will now liquefy and cure to produce the strengthening and bonding layer required.

Pre-preg Carbon Fibre parts are lighter than the same parts manufactured using the wet lay-up technique but Pre-preg parts have a higher cost due to the extra process required.

Carbon fibre parts are lightweight, making them ideal for bonnet lamp pods, door cards and roof vents. Carbon fibre also offers a neat finishing touch for areas where standard equipment has been removed, such as a boot liner, centre dash panel or firewall.

Carbon Fibre Rally Car Parts - suitable for Subaru impreza and Mitsubishi Evo
Kevar Rally Car Parts - suitable for Subaru impreza and Mitsubishi Evo

Kevlar

Kevlar is a registered trademark for a lightweight aramid fibre, which is woven into the mat used to produce the require parts. The fabric is laid across the mould, resin is then added to the fabric, which once cured creates the bond between the layers and also a solid coating holding the Kevlar reinforcement in the required structure shape.

Kevlar is most widely known for it's use in bullet resistant clothing, due to the material's ability to absorb high energy impacts. Components such as sump guards are ideal to be manufactured from a Kevlar based composite, giving the extra protection required.

Twintex

A composite material composed of thermoplastic and glass fibres, which is formed across the required mould in its fabric state, then vacuum bagged and heated to the required temperature, where the plastic fibres liquefy and reform to produce a solid protective layer around the glass fibre reinforcement.

Twintex has been designed to offer high mechanical properties such as excellent stiffness to weight ratio and also superior impact properties. This makes Twintex ideal for rallying parts such as under floor guards, sills and arch liners.

Twintex Rally Car Parts - suitable for Subaru impreza and Mitsubishi Evo

Glass Fibre Rally Car Parts - suitable for Subaru impreza and Mitsubishi Evo

Glass Fibre

As the name indicates, glass fibre, also known as GRP manufactured from fine fibres of glass, that are woven into the required mat. This mat is applied to the mould, followed by the resin as a bonding and strengthening agent. The covered mould is then left at room temperature to cure and once the curing process is complete, the part is removed and any excess material trimmed.

Glass Fibre has been used for many years as a composite material for replacement parts, offering a lighter weight advantage compared to standard manufactured steel components. A glass fibre component is also a cheaper alternative to the equal Carbon Fibre component. Parts ideal for manufacturing from Glass Fibre include bumpers, bonnets, mirrors.

 

If you are uncertain of the material / resin required for your application, please call us where we will be able to discuss your options.