Henleycraft Ltd

Specialist Manufacturers of Glass Reinforced Plastic Components

Taxi Project
Gallery
GRP Moulds
GRP Materials
Vac GRP
GRP Mould Clamp
Planters
Racing Car Project
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Racing Car Computer Model
During 2003 Henleycraft was approached to produce the tooling and initially the prototypes for a road legal, single seater Kit Car.
Racing Car Concept Rear
Racing Car Concept Front
Once the concept was finalised a PU Foam Pattern was built up in sections and hand crafted to the required shape.
Race Car Foam Pattern Front
Parting Flanges

Racing Car Project

Race Car Foam Pattern Rear
Filling of Foam Pattern
A solid model was designed on CAD by the customer and various different designs were considered and modeled on computer before a pattern was produced.
The PU Foam Pattern was then prepared with filler and primer polyester coats and flattened to a smooth finish.
Painting of Foam Pattern Front
High Gloss Rear
Painting of Foam Pattern Top
Painting of Foam Pattern Rear
GRP Mould Side
High Gloss Side
High Gloss Front
The Pattern was then sprayed finally with a high gloss black finishing coat. The next stage was to address any minor imperfections with fine wet and dry paper. The whole pattern was then polished to a glass like finish.
GRP Mould Clamp Top
GRP Mould Clamp Side
GRP Mould Top
GRP Mould Rear
Assembled GRP Mould
Kit Car Front
GRP Race Car Rear
GRP Race Car Front
Kit Car Rear
GRP Race Car Top
Parting flanges were then built around the pattern in the appropriate places to allow for the mould to be manufactured in six seperate components. This enabled the dismantalling of the mould for the finished GRP moulding to be removed.
GRP Mould Clamps were extensively used in the manufacture of the moulds to allow for the ease of assembly, alignment of the moulds and to create a near perfect seam on the finished moulding. (see GRP Mould Clamp link).
Once the mould was complete it was released from the pattern prepared for manufacture and the six seperate moulds were then bolted together. The use of the GRP Mould Clamps insured the moulds were perfectly aligned.
The completed moulding ready to be delivered to the customer
The car was then built up around a space frame chassis and the use of major components salvaged from an Audi 100.