OldAndyAndTheSea Posted March 26, 2018 Share Posted March 26, 2018 (edited) Without a cage, or monocoque design, quite frankly, I wouldn't. But if you want to go down the rabbit hole, you must include some sort of load bearing/dispersing core within the laminate. Most F1 racecars are constructed from a combination of aluminum, and nomex, honeycomb core. Aluminum is best used for crumple zones, and is highly structural, while nomex is designed for excellent fire resistance, but isn't as structurally robust. Nomex is significantly lighter, and subsequently more expensive, than aluminum, so it is used only where advantageous. So the survival cell (Monocoque) sees this type of core most often. I'd build a totally composite version, with aluminum honeycomb (3-5mm) core. Imagine if you were to take an s30 door and cut the inside skin off. I'd make that idea, and then build a semi structural door panel that goes over the inner workings of the door, because I also would want to retain window function and such. Horrible description, but eh I'll roll with it. I really dislike the idea of making some bastardized door hybrid out of 40+ year old existing shells and single skin, hand laid, laminates. That's not safe. Nor is it truly using these materials as intended. It's like if someone decided to build a carbon fiber house...and they start by making a bunch of carbon fiber 2x4s.....sure that will work, to some extent I suppose, but it isn't using the materials to their advantage. Unless the person really knows these materials (at an Aerospace / ISO 9001 level) you really shouldn't be making your own doors, in my opinion. Not the task for the average body guy. I feel this is an aesthetics game, hidden beneath a "weight savings" veil. Edited March 26, 2018 by OldAndyAndTheSea Quote Link to comment Share on other sites More sharing options...
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