As the molds are finished we’ve started to manufacture the new bodywork. This is being done by carbon fibre casting. Carbon fibre is an extremely strong and light material, which in recent years has become the obvious choice when light weight and strength is being prioritized. For example, Formula 1 car bodies are built up of carbon fibre.

The carbon fibre mat is very flexible, making it optimal even for difficult geometries. The carbon fibre mat is supplemented with epoxy as binder, which then is being vacuum bagged to allow the bodywork to harden.

Have a look at the gallery below to see how it works!

The carbon fibre mat is being cut.

The carbon fibre mat is being cut.

Epoxy is added to the first carbon fibre layer.

Epoxy is added to the first carbon fibre layer.

The carbon fibre mats are very flexible.

The carbon fibre mats are very flexible.

There are no problems to shape the wheel housings.

There are no problems to shape the wheel housings.

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Models in 1:10 scale of Nova and our new bodywork has been tested in a wind tunnel.

The test was performed in six different wind speeds between 5.4 m/s and 19.6 m/s. The results indicates a reduction in drag force by 20 percent in a comparison between Nova and the new bodywork.

As the wind speeds are lower relative to the model size, the results are not directly applicable to the full scale model. Though we expect an even greater improvement in the end. The computer simulations which were previously performed helped us achieve a good result.

The work on the plug proceeds and right now slices of the plug are glued together. Take a look in the slideshow below for some pictures of the tests and the progress.

Slices of the plug are glued together.

The new bodywork in the wind tunnel.

Nova in the wind tunnel.

Random data and graphs from the tests.