Well when Dave Kern starts something he is most likely going to finish it. I mean seriously. His wife Allison recently recounted the time that the motor blew during a race, fire was shooting out of the hood, over the car in large balls of glowing heat and she had to tell him that it was over, they had to pull over. Well, this same determination goes for fabrication of the ultimate race car too.
This years car features a complete composite body, about half of which is being fabricated by Dave with a bit of help from me. The other half are commercially available parts. The new car will feature larger, stickier tires, more elaborate aerodynamics and a full flat bottom to also aid in the aero. Wow, it is a ton of work and wow I wish I had more time to help him out because I feel bad that he is going at most of this alone!
Check out some photos from the build so far.
My composites professor from Metro has decided to tackle the front aero. With a brand new splitter that should actually weigh about 1/3rd of the weight of the current splitter… well this thing should be mean
Check back for more and check in with RaceKern for even more details on the build.
I don’t know why I forget this stuff, but I am remembering how much work making a mold is… Yeah. It is one of those things that I remember when I really think about it, but when I haven’t done it for a while I convince myself that it will just take a few hours.
If you haven’t seen part one of this build check it out here. This time I have been going layer after layer, working my way up and trying to get a nice smooth final product. There have been some tricky parts like the airbag area and the vent holes. In addition the portion that I have made with foam is a bit tricky as well, occasionally when you get beyond the bondo layer you find out what happened very quickly when you hit the soft foam! I reached a point where I needed a much better visual indicator of what was going on. So I had to put a coat of glossy paint on in order to see the lines better than I could with the flat primer. So I chose a red paint and painted it up. It gave away some issues immediately. There were some sanding marks that were a bit deeper than anticipated, some waves that I needed to sort out and basically it just did exactly what it needed to do.
So I did a full wet sand on the part and really smoothed it out. some spots got all the way back to bondo again through the paint layer and the primer layer. Once I got it all smoothed out another layer of glossy red and WOW! what a difference! It looks very good right now. There are a few little imperfections, they are all pits and will actually be easier to fix in the mold itself so I am going to leave them and sand them out of the final mold.
After the mold was fully prepped we took aluminum tape to create the rest of the part. Basically the part needs draft, so using the tape is much faster and easier to shape for portions of the mold that we don’t care about. Plus it doesn’t really stick to the fiberglass, so that helps as well.
I believe that there will be two more parts to this project, one more for the mold making and one more part for the final part that we pull off the mold. Check back soon!
I’ve been living vicariously through some of my friends by helping them with their race cars. Mostly I’d say it has been Dave and Allison Kern. Originally I had helped them with some work on their Pikes Peak Hill Climb Evo. I did a bunch of work on their aero package, but also ended up welding some parts as well as installing and fitting body parts as well. It is fun to get to work on this stuff. There is a lot of problem solving and a lot of building, creating and working with your hands. Currently they are working on the creation of a BMW rally car.
The BMW will be used as a 2wd Rally car. It is cheaper to run and compete in and with a privateer budget that is good news. It is also going to provide the opportunity to run in Max Attack which is a 2wd specific rally event that will give them good competition in an affordable package. If all that wasn’t enough the BMW will be set up so the drivers seat is able to accommodate a shorter driver or a taller one…so Allison now has the ability to drive!
The car has been caged by SCR Performance but Dave is taking on the majority of the rest of the work. The beginning steps (beyond all the research that he has into figuring out the parts for the car) is the underbody. The BMW isn’t exactly designed for Rally, so you have a couple options. Paint the car and replace the chassis when it gets wrecked or try to protect the chassis. The plan for this car was to protect the chassis with Kevlar and Macropoxy. Macropoxy is a paint that is a good barrier against rust and light impact. Kevlar, well that takes the bigger dings and dents well. The EVO Works well with the Kevlar under body, but it is separating a bit in places, so this time we tried a few different tricks to try to keep the body and the kevlar together.
The Kevlar now has epoxy that has been seeped into all the welded seams so it hopefully gets more adheason, also we put chunks of Kevlar into some of the gaps between seem welds so those will hopefully give the kevlar even more places to adhere.
It is a messy process, so we only have a few photos of this part. This is what the end result looks like. Almost time to flip the car over and start putting parts on it!
I’ll be helping them out whenever I can, so keep an eye back and I’ll post up some progress as we go. In the mean time you can check them out on Facebook
Kern Racing Fan Page