|OEM Banner battery in Caterham R500D engine bay.
|Standard Battery Tray in Caterham R500.
|Battery Cage removed and weighed in at 464g
|Banner Battery weighing in at 9.2kg
I then needed a mould to lay my carbon fibre onto, so measured up a rough template and got Nigel from Specialist Sheet Metal in Stevenage link here to make me one.
|Carbon Fibre bracket template
|Carbon Fibre Laminating Starter Kit from Easy Composites
|Epoxy Resin and Hardener being weighed
|Mould covered with one coat of the adhesive solution
|First sheet of carbon laid onto mould, with another coat of adhesive solution
|Second coat of carbon fibre sheet laid with another coat of adhesive solution
|Third and final sheet of carbon fibre laid
With the part completely hardened, I could out the cardboard I'd used to protect my flooring (as the adhesive went everywhere this was a good idea!) and then gently prised the part I'd made away from the template using a wall paper scraper.
|My first carbon fibre part ready for removing from it's mould
|Battery, cage and bracket in place and marked ready for cutting
|Carbon battery cage and bracket weighed in at just 282g
|Odyssey Extreme Battery with Bespoke Cage and Housing in Caterham R500