Creating UBERCLAM! Was "Repairing the clam"

[FredVa1]

'07 Exige S. I have been doing HPDE-2 with NASA at VIR and both Summit Point Tracks, going to HPDE-3 (passing anywhere with a point-by), eventually want to get licensed and race the Exige with NASA. (As one of very few out there, even in HPDE everybody wants their video to show them pressing the Lotus, so you get plenty of action). Scrambling to catch up with you guys on clamshells cracks, etc. Dont want to overburden the forum, but would help if there is a catch-all article/site somewhere you could point me to to read up on: 1. when the damage to the shell is too much to fix, must replace (I can just about afford to race the car, getting HANS, harnesses, maybe cage). 2. Anything else about racing the Exige, (does Lotus sell the cage, do you advise having one fabricated, CDOC shop is close by. If I get hit hard enough to damage the frame - will that be the least of my worries?). I am hooked on the Exige, slowing getting better at exploiting it. Could better afford to race spec Miatas or something, but just dont know if I could like it.... thanks for listening to the rambling. I know I am asking mostly about going off track, etc, but there is lots of data out there about going faster, etc, very little about what happens when it all goes to sh*t.

[malc]

Hey Randy,

What news of the uber-clam? Is it standing up to cone abuse?

I removed mine today and spent the afternoon stripping off a few yards of ducktape. That gorilla super tape is really strong. My clam is not quite so far gone as yours was, I think I can get away with patches to repair the major damage.

I would like to stiffen up the front and bottom with foam. I think that the best strength-weight combo might be a sandwich of glass and 1/4" foam blanket. We used this stuff for making racing sailboats and got incredible stiffness and strength to weight. If you get too thick with the foam you get stiffness without strength.

Any thoughts?

Malcolm

[Noizemaker]

Just wanted to post and say "Thank you" for all the pics and information in this thread. I'm getting ready to embark on my own uberclam, and the information in this thread is priceless. I'm gonna go about a couple things differently, but the amount of tips in this thread is crazy.

[Randy Chase]

You are welcome. Glad it provides some help.

[Noizemaker]

Okay, bump from the dead to ask if you remember where you got your A B foam? I can't find it locally anywhere and I don't want to order online if I can help it. It's been like 3 months now running around cracked, with a cut/braced clamshell upside down on the back of my Neon (helluva workbench, i guess). I've been working insane hours at work, but on my next day off I'd kinda like to get foam in there, if i could figure out where to get it!

Any leads?

[kmt63]

you might try pegasus race car supply.they use this a/b foam for race car seats.or a good composites supply.i bet tap plastics would have it.

[Noizemaker]

Originally Posted by kmt63

you might try pegasus race car supply.they use this a/b foam for race car seats.or a good composites supply.i bet tap plastics would have it.

Yep, to anyone lookin', TAP has it. $45ish for 2 quarts.

[malc]

I had mine fixed using fibre glass and Panelbond 2 pack epoxy. Very strong and light. I am very happy with it.

[kmt63]

Originally Posted by malc

I had mine fixed using fibre glass and Panelbond 2 pack epoxy. Very strong and light. I am very happy with it.

the a/b foam is used for reshaping missing pieces.then you lay glass over that to make it strong.