The weight saving thread

[richie]

[
Fredrich, what do the remmele doors look like on inside?, all cut out or have factory style pressing?
cheers Richie

Flat on the inside. Very nice fit but no enforcement or ribbing.

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Thanks, i did contemplate doing it like that, wold have been much simpler but am sure it would need to be thicker to have similar strength

cheers Richie

[richie]

That door looks amazing 

Not knowing a lot about this at all, I assume they are two pieces bonded together?

Yep just like a stock door, 2 pieces joined together

[leec]

Very impressive.
Are they going on the pan cab or the chassis cab?

[richie]

Very impressive.
Are they going on the pan cab or the chassis cab?

Chassis car, I haven't even seen the other car for 2 years nearly!!!

[richie]

Both sides are now done, decided to fabricate my own hinges as the stock VW hinges are really heavy, with everything I removed  weight saving is 31lbs per side[just over 14kg] so total of over 60lbs is huge    I will add some lead right at front of car now to help the front to rear weight balance and car will be lighter as well

[Frallan]

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How about this weight saving?
The company I work for (Composite Design Sverige AB) has been on the journey with Koenigsegg since the first prototype.
So a lot of inventions started here. Like the CF rims. Since some years they do them inhouse. But we did several hundred.
This one is built for Micke Svens Spezialmotorer.
He does retro axial driven horisontal cooling for Porsche racing engines. We deliver in CF and regular epoxi fibreglass.

[Frallan]

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This is what was manufactured by us and used in the world record holding 407 km/h Koenigsegg run in USA.
Niklas Lilja, the driver not only likes the rims but says that with that huge reduction in large diameter rotational weight, the car behaves significantly different in many ways, handling, braking and acceleration. All improved so much he can simply feel it.
Not for us VW freaks (yet) but very cool!

[Frallan]

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Last one and what I expect to see soon on our cars.
The Koenigsegg valve covers. This is not so difficult to do for our engines.
Who will be first?

[Frallan]

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Ha ha ha! 
I had a visitor at work and when I saw these in the conference room, I could not hold myself.
How about this 2 kg weight saving?
Engine rotational mass! Not just on the car.

No, stop before you get lost in dreams, the design and purpose is for OEM engines, that are usually not opened/serviced.
They are glued in place with a special tool.  Yeahh and a special glue.
Well, in fact there is a tool to take them apart too.
No engine has run with them yet, but I can say that the theoretical numbers for fuel savings, makes them very interesting and gives a payback.
Not for aircooled VW engines and not for racing, as designed today.

[richie]

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Last one and what I expect to see soon on our cars.
The Koenigsegg valve covers. This is not so difficult to do for our engines.
Who will be first?

Some very nice parts Frallan   Like the fan & ring a lot  

I made valve covers for my engine already but have not used them as was concerned about the heat aspect causing it to leak

cheers Richie

[Eddie DVK]

Whooooooooooooooo 
Frallan, that is impressive, damn cool.

[mikko k]

Very very nice parts! 👍 But not for poor racers.. 😥

[andrewlandon67]

So I was chatting with some buddies last night and I came up with an idea for a rear-seat delete made out of canvas and a couple of strengthening ribs. My idea is to have it anchored at the points where the rear seat crossbar is bolted down, then have it stretch up and hook into the little metal extrusion for the rear parcel tray carpet, with one rib running across the middle, right where it meets the rear wheel wells, and one running across the front, between the anchors, to keep it from pulling too far back. It's obviously still adding weight over just taking everything out alltogether, and it's not quite as practical as a big storage box, but I think it's a neat concept that could be done cheaply and still look good enough for a street car, while providing the necessary "cover" over the battery. I'll try drawing it up later this week and upload pics here.

[karmi]

 

[karmi]

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[karmi]

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[karmi]

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[richie]

Nearly a year ago I said i was going to make some big window beetle carbon doors, finally got round to it now, and small window doors will be available to in next week or so, all the moulds for both early and late are ready to go. this is 1st late outer out of mould today

[Fastbrit]

Great work Richie!

Just wish I could afford to get some 914 doors done in CF! The weight saving would be even more impressive as the later 914 doors have side-impact bars incorporated, access to which is hard without chopping up the doors.

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[richie]

Great work Richie!

Just wish I could afford to get some 914 doors done in CF! The weight saving would be even more impressive as the later 914 doors have side-impact bars incorporated, access to which is hard without chopping up the doors.

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Thanks   am surprised no one makes lightweight doors for them already then with that being the case

[Fastbrit]

You can buy glassfibre doors (in theory - delivery is sketchy to say the least) but they're £1500 a pair plus carriage and the rest from Germany...

[richie]

You can buy glassfibre doors (in theory - delivery is sketchy to say the least) but they're £1500 a pair plus carriage and the rest from Germany...

that seems way to much for glassfibre, can't see anything special about the doors that would make them time consuming to make to justify that cost Wish I could get that much for glassfibre cabrio doors!!!


Anyway back to the carbon stuff, other late outer is done 

[richie]

Am sure the cheapo plastic headlight rings are light but made these to replace some aftermarket steel ones, decent saving   

[richie]

 

[ibg]

What  very nicely made 'bit' is that?   

[mikko k]

What  very nicely made 'bit' is that?   

Cover for turning signal at front wing.

[richie]

What  very nicely made 'bit' is that?   

What  very nicely made 'bit' is that?   

Cover for turning signal at front wing.

Yep, was given some moulds and moulds for these were in box so had to make some

[richie]

One negative to the carbon decklids was using the stock steel hinges, they are nearly 1/3rd of the weight of a decklid which is crazy   I have started looking at 3d printing as an option for making small parts moulds and this lead into trying to make some hinges, got one half of one made just to see weight[ I didn't make this myself, someone I know made it for me] and it is certainly light so now to make 2 complete hinges and see how they work 

[richie]

I got some 3d printed hinges finished and on a couple of cars now testing durability, when I went to fit up a carbon door i started thinking about how much all the bolt on stuff weighs, most of it doesn't need to be that heavy as it will never see the millions of day use VW allowed for in the original design. I did some research on "forged carbon" parts and made my 1st mould, this is result A decent weight saving but it can be so much thinner than the original in the handle part as its solid compared to stock being hollow. 
Working on some other moulds now that this worked

cheers Richie

[richie]

1st part of the door hinges, 55g compared to 209g for the factory part