Honeycomb Panel

[maguromic]

Anyone have a good source for honeycomb panel on the west coast or know someone with some scrap panels or surplus. I need it to fabricate my tub for the REMR. I need it to be at least .025" skin and more than 3/8" core density. Thicker skin and denser core (say 1/4" cell) is even better. Aluminum, fiberglass, or nomex core will do. Tony

[Glen]

Try AirCraft spruce in Corona, Ca.

[Stainless1]

Boeing surplus usually has some here in Wichita.  I will check Wednesday (the only day they are open).  How much do you need?  They usually have 3x5 sheets, as well as smaller pieces.  I also have a connection at another aircraft company that might have some as well. 

[maguromic]

Stainless, I can cut all the panels out of a 4x8 sheet, but I could do it on a few smaller sheets also. I would really appreciate it if you could let me know what they had.  I will call you tomorrow on the engine, I think I can be of some help on it. Tony

[John Burk]

Take a look at this stuff .

http://nida-core.com/english/nidaprod_honey_h8pp.htm

Wish I'd known of Nidacor honeycomb when I made my body . The Composite knits to the surface . 3/16" bends in a 4" radius simple bend and maybe a 3 ft radius compound bend . My friend gave me a sheet but I never had a chance to use it for anything . I think a body could be made by fastening it to the buck with thread and laying it up .

John

[A2WindTunnel]

Plascore:
http://www.plascore.com/product-honeycomb-cores.htm

This is a company we use and have had good luck with their products.
.

[Dean Los Angeles]

ACP Composites is in Livermore.
http://www.acp-composites.com/home.php?cat=4708

[maguromic]

Thanks for all the leads.  The ideal size would be a 4x8 sheet as I can cut everything out of one sheet.  But I could do it on a few smaller sheets also.  Tony

[Dean Los Angeles]

Anyone have a good source for honeycomb panel on the west coast or know someone with some scrap panels or surplus. I need it to fabricate my tub for the REMR. I need it to be at least .025" skin and more than 3/8" core density. Thicker skin and denser core (say 1/4" cell) is even better. Aluminum, fiberglass, or nomex core will do. Tony

Scrap or surplus may mean defects. Have you done strength calculations? There is a huge difference in tensile strength and shear strength between the cores you mentioned. You didn't mention the face material, and that also has a great deal to do with strength. Aluminum face? What alloy? Fiberglass? 2 ply, 4 ply? Even at a 1/4" cell, 5052 aluminum core with .004 wall is 5 times stronger than 1/4" cell, 5052 aluminum core with .001 wall.

[maguromic]

Dean, We want the aluminum face in any available alloy at least .025" thick.  If we were going to have to form the edges on the skin the alloy would matter and in this case even the softest skin alloy  (probably 5052-H32) is fine. There are sometimes much stiffer skins available, but they are actually slightly less preferable in our case. The reason the core can be not-the strongest is because of the way we are using it. It's not a structural member, it's a container where it's meant to give (in a nice manner) if your body-slams it in a tumble.  My preference would be the .004" alum core, but the softer core would work fine- just dent easier. 3/8" cell is getting a little too coarse unless it's pretty thick  (.007"+) cell wall.  Thinking about it a little more I'd rather pass on the nomex core unless it's pretty fine.

Peel strength is also not an issue here, nor is bending. About the only thing that can get too weak here is the skin thickness- then the fastening points would be insufficient unless you use a zillion of them.  The basic design is to keep the driver safe from objects protruding in and hitting the body and also to be able to take the load of the body and give when tumbling.  It’s not going to be a feather bed, but it’s going to be a lot better than hitting a pipe or a stiff panel. Also it needs to be able to come out in parts for cleaning.   My friend Steve who designed the tub has over 25 years in designing tubs for some of the top teams in IMSA and CART and feels this is a safety necessity for us, as we want to try and interject some science and take out much of the relying on luck playing a roll in a crash.  In the next few days I will try and update with better drawings of the tub in my build diary. Tony

[javajoe79]

 Finish Line Composites is Benecia might be worth a call. They do alot of work for all the shops at Sears Point. We used them alot when I was with the world challenge team. I can't remember the owners name but he was a one man show at the time and has since expanded. Real nice guy though, used to work for Boeing I think.