Photos and Case Study with kind permission of ADR

This case study details a recent project completed for ADR Engineering. All procedures detailed were completed in house at our two Derby sites.

We were delighted to be approached by ADR early in 2005 to look at the production of GRP body panels for the new ADR Sport 3 car, due for launch late 2005.

ADR has it roots in a 1950`s general engineering company supplying to race and non-race industries alike. In later years the supply to the race industry changed from just parts to whole cars with the launch of the successful ADR Sport 1. The Sport 2 followed with the Sport 3 evolving in 2005.

We received CAD data from ADR and machined a scale model of the car for wind tunnel evaluation. The information learned here was used to improve aerodynamics ensuring down force and air intake for engine cooling. Some changes were made to the CAD data and we began machining the Master Patterns. All the patterns were machined on our Correa Prisma 20 which has a machining envelope of 2m (X) x 1m (Y) x 1m (Z) and were made from a synthetic model board.

The patterns were then sprayed with a reface and polished back by hand to a high gloss finish ready for mould tool production. The production tools were made at our Composite Products site and prepared for production running. The panels required are the front (pictured), the rear, side-pods and centre section.  

The production parts made have a gloss level of 80% - 100% and each car can be produced to a customers exact colour requirement, cutting out costly body spray procedures. We also work to specified layers of fibreglass ensuring weights are kept to a minimum and that panel weights are consistent. All panels are inter-changeable and fit together with a moulded male / female location system.