Autoflock MotoRSport Current Updates & Pics

[Autoflock Motorsport]

Hello everyone,

some of you may already know me but for those of you who don't my name is Raj and I run Autoflock MotoRSport located in North Wales, the company specialises in:

• Electrostatic Flocking
• Blast Cleaning
• Powdercoating
• Carbon Fibre, GRP & Aramid Composites
• Official dealer for Polybushes

All the above services are completed in house and are not out sourced.

I have been on this site for a while now but only very recently have become a trader so I thought I would introduce myself and start a company based thread.

I shall be updating this thread frequently with pics and information regarding the current work/projects being undertaken, it will also be a good place to answer any questions you may have so please feel free to comment/subscribe.

Later today I shall upload a few bits and bobs regarding previouse work and also some more up to date so that you are all aware of exactly what we do.

I look forward to speaking/meeting you all soon, thanks for reading.

[Autoflock Motorsport]

Few pics of some intricate blast cleaning
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[Autoflock Motorsport]

Some powdercoating
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[Autoflock Motorsport]

Here is a few pics of some composite work
Red top heat shields and universal naca duct
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Custom bonnet for a hillclimb saxo, this needed this to be strong but light as possible, so we did our best and produced this bonnet which weighed in at 1.8kg. Not bad
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[Autoflock Motorsport]

Fiesta carbonfibre roof, this is our normal spec roof for the general public, weighs 2.3kg

[Autoflock Motorsport]

Little job I knocked of for a friend, zetec plug cover with focus rs embossed into the finished part
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[Autoflock Motorsport]

Here is a couple of pics of a custom escort series one dashboard I had in for a custom guage pod, major crack repairs and flocking.
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[Autoflock Motorsport]

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[Autoflock Motorsport]

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[Autoflock Motorsport]

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[Autoflock Motorsport]

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[Adam B]

Nice work,

What's the price of a custom bonnet roughly?

Thanks,

Adam

[Autoflock Motorsport]

Nice work,

What's the price of a custom bonnet roughly?

Thanks,

Adam

Hello Adam,

that's impossible to answer as it will all depend on what is required and spec ie. is it to be a direct replacement? does it require oem inner fitments such as hinge locations and latch locations? is it just to be a single skin held on with bonnet pins?

them more time involved the more expensive, but usually the lighter the product the cheaper it is, especially if it is a generic part which can generate further sales.

Are you asking for carbon parts for a fiesta zetec s??? if so I may have some interesting news ;-)

[Adam B]

It'd be a bespoke item for my mk4 fiesta.

But by all means, spread the news...

[Autoflock Motorsport]

I have mk5 bonnet and boot I will be on with moulding leter this year, but I dont have a bonnet for a mk4. What sort of spec would you require? And would it be a one off or could you help generate a efw more sales? 3 ideally as then I could take the hit myself on producing the mould.

[miikk]

Love the look of the finished dash panel,very nice work.
How much for one of the Focus RS plug covers?

Cheers.

[Autoflock Motorsport]

hello Mikk
plug covers are £70, I was thinking of doing a group buy for 10 though at a special price, just need someone to help kick off a thread on any relevant forums to get the ball rolling ;-)

[Autoflock Motorsport]

Here is a few pics of a custom 2 tone Impreza dash and steering wheel
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[corblimey3.1]

that looks very smart

[Autoflock Motorsport]

Here is a few pics of a small bit of work we have done on a Focus MK2 ST. Just brightened up the door cards and a bit on the dash/centre console.

Standard door cards
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Drilling the plastic welds out to seperate the various panels which make up the door cards
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Seperated components ready for preping
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All flocked and ready for bonding back together, I think it looked much better with the new colour scheme
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Thanks for looking

[Autoflock Motorsport]

Here is a few pics of an escort mk3 bonnet I have been working on for a friend, its been a long and ongoing project and there is a few pics which I cant seem to find as I have changed phones, but hopefully these should give a few people an idea of what goes into making a composite panel.

Prepping the outer mould ready for fabric


1st layer of fabric



Next layer is peel ply to allow the flow media to be removed from the stack once cured


Next is the flow media, this allows the resin to pass over the fabric and replacing what little air is left from the vacume giving the next best resin to fabric ratio compared to pre-preg fabric.


Vacume bag sealed to the mould


Vacume applied, this is a key step as the fabric has to be carefully worked into the contours of the mould. Great care is taken to ensure the weave stays as neat and consistent as possible.

[Autoflock Motorsport]

Once I am happy that there is a 100% seal and no leaks I can start to allow small amounts of resin into the part, taking care not to over fill the part so I ensure full vac






Now the mould is subjected to an elevated temperature and the part is allowed to cure.

[Autoflock Motorsport]

Once the parts has been cured and post cured it is now time to remove the excess media






At this point the parts now needs to be gently teased out of the mould. This is where all the mould prep comes into its own




This is straight out of the mould so a good poilish will bring up a lovely shine without the need for laquer.

Triming the panel is the next job, these centre vents are the bain of my life

[Autoflock Motorsport]

The main feature of this bonnet was that it needed to be an oem replacement so the hinge locations and centre front latch location/mounting points had to be retained. This is where it got tedious.

The standard frame have a lot of lightening holes in it which are a nightmare when moulding. The only way around this was to make a mould of the standard inner frame from a standard metal bonnet, then replicate it in grp so that I could then use filler and other materials to perfect the surface. There is also a returning edge around the frame which is not needed so I was able to remove this as well. Took a lot of work though to get the final mould.

[Autoflock Motorsport]

standard inner frame mould


Producing a grp inner frame



Grp inner frame now removed from mould to be perfected and smoothed

[Autoflock Motorsport]

first up was a lot of wet and dry sanding


both sides were subjected to this


now filler was used to smooth out the imperections which had transferred from the metal bonnet

[Autoflock Motorsport]

once I was happy with the finish of the inner frame I then placed it within the outer frame mould so that I could remould it with the correct location reference points, this is important so that the top skin sits perfect within the cars shut lines. Soft wax was used to seal the edges









Again more wet and dry samding with 800, 1200 and 2000 grit



The plug is now ready for release agent

[Autoflock Motorsport]

now on with the moulding process











Bracing added to prevent shrinkage and distortion

[Autoflock Motorsport]

once cured the plug can then be seperated from the new inner frame mould



After a lot of wet and dry sanding and a good machine polish this is the final result

[Autoflock Motorsport]

Now as with the outer skin, i can begin building up the composite stack













And the final part straight out of the mould

[Autoflock Motorsport]

final trimming and fixings to be installed onto the inner frame



front latch location holes



Hinge location holes



Trial fitting a standard latch



The fixings used were m6 threads same as oem, now these were installed and the parts has been fully trimmed a final wet and dry and a polish was done

[Autoflock Motorsport]

using the resident locations and a jig I placed the 2 frames together and bonded with panel bond

[Autoflock Motorsport]

And the final product. note how the edges on the inner frame stay fluch with the outer skin unlike the oem one, small detail which may go un noticed but a lot of effort was put in so this could be achieved.

[Autoflock Motorsport]

and fitted to the car, this was before it was adjusted to allign the shut lines and panel gaps









For this actual project the bonnet will need further re-inforcing as at the strip we found that there was some deflection upon reaching 150+mph due to the vac the car was subjected to with winds passing through the engine bay, this will be overcome with a modified stack and a slightly more recessed front latch location. Still this weighed in at 3.6kg which is not bad considering its an oem replacement.

Thanks for looking

[gorilla1q]

Some great work happening there

[Sunbmw]

Fantastic job there, well done.
So, just as a guider, what price would you have to sell that bonnet at retail? I am intrigued as I have quite a bit of custom carbon work I might put your way. I am aware that the mould making process is one of the most time consuming jobs, but would love to know if it is affordable or not.

[Autoflock Motorsport]

that bonnet is £540.00 delivered as it is a generic fitment, but it all depends on the product, for example I could do a bonnet to be fixed with 4 x pins which would weigh in at around 2kg for approx £300 - £350 mostly due to the time. I have no problem in responding to price requests shoudl you wish to ask, also if you wanted included confirmation of the materials used, I dont use any polyester resins for my composite infusions and only mix fabrics on customer request which would only be carbon & aramid. Never use diolin (imitation carbon) .

[Autoflock Motorsport]

@ gorilla - thanks very much :-)

[Autoflock Motorsport]

@Sunbmw - as a guide, if you look further up the thread there is a saxo bonnet, this was for a customer who wanted a bonnet as light as possible for his hill climb car, he provided the bonnet and did a fair bit of prep himself to save on my labour costs, a custom mould was created which incorporated the aerocatch locations, the mould and the final part cost the customer £400, I gave a good discount though as they also provided me with some templates for door cards which are always popular.

[Autoflock Motorsport]

Here is a few quick pics of a small project I recently finished for a friends 4x4 cosworth powered fiesta, its a centre panel to go on top of the tunnel. I suggested using the original metal ally plate which he had made and flocking it, this can then be bolted in place, but in regards to the switchgear/fuses to have a composite plate within the metal facia which can then be removed for maintenance etc. I produced a a recessed panel which I think finished the panel of really well. See what you think