We recently had a brilliant opportunity to have our development BMW M4 G82 reviewed and videoed by Paul Wallace from the super popular YouTube Channel, SuperCars of London. It was great to be part of the video and get his thoughts on the car itself and also the new M-Performance Style exhaust system by Quicksilver.
Paul Wallace is a 32 year old Supercar enthusiast who started his first Youtube channel in 2006. Now Supercars Of London (SOL) has 885,000 subscribers and over 300 million views and is one of the top five car vlogs in the world. From reviewing the latest cars, road-tripping around the world in the fastest, most exotic of cars through to the purchasing of his very own supercar.
The main bulk of the day was for Paul to get a feel for the car and the new exhaust system that Quicksilver have developed as an alternative to the BMW option.
Paul is known as the resident “Exhaust Expert” and it was great for him to check the car out and get his thoughts and surprise to hearing the system in action!
As per normal he filmed an excellent YouTube video on the car and you can check that out below!
Here at Carbonwurks we are no strangers to high-end cars and repair work on carbon fibre. Normally in any given week we will be repairing carbon fibre on Aston Martin’s, Bentley’s, Ferrari’s or for rare and exotic manufactures but this McLaren 600LT ranks up there for one of the most special!
The customer came to us with a handful of videos and photo’s of the damage which McLaren themselves had quoted over £16,000 to replace! The damage for the most part was cosmetic with some light cracks to the structure in places. This turned out to be a challenging but very rewarding job for a few reasons.
Firstly, we disassembled the car which included removal of the wheels, inner arches, headlights, inner tub, lower undertray/floor before then removing the bumper and disassembling the various individual components which could then be repaired.
With all the parts removed, it was back to our repair shop to start addressing the carbon. The first part is to ascertain the level of repair required to minimise time and cost to the customer. Some parts needed light sanding and resin infusion to level the finish whereas others needed a significant more work to make sure the part was structurally sound.
The front carbon pack on a 600LT is made up of 4 parts – front aprons/splitters (left and right), the middle main bumper section and an undertray. Interestingly, these McLaren parts are made with a 2×2 Twill for all apart from the lower undertray which was made using compressed forged carbon and left in a resin-finish (not lacquered). With the undertray not being exposed to UV or visible to the eye, leaving the part un-lacquered saves weight as well as cost.
These parts over the course of 2 weeks were strengthened and rebuilt with our in-house specialists before heading off to lacquer. The undertray originally we wanted to keep a resin finish rather than lacquered to keep a close to original look as possible but in the end with the level of scuffing and scratches, the part needed to sealed in with lacquer to give a more uniform finish and ensure the fibres would not suffer exposure damage over the course of it’s life. We did manage to obtain a close OEM level of gloss and as a by-product a more uniform finish.
Once the parts have been clear coated and baked, they go through a strenuous quality check procedure to ensure a super smooth, pin-hole free finish. Finishing a part is as important as producing or repairing a part, fortunately with thousands of parts being produced yearly, we have got pretty good at doing this!
With the parts signed off, these went back to the garage to get installed. The processes is the reverse of removal along with some minor repair work of a few fixings points that had previously been repaired or damaged in it’s past life. With very stiff components and stiff chassis cars (carbon chassis or solid suspension bushings/components), this is quite common and can easily be made structurally sound again to stand the test of time.
We captured the process which can be viewed on our YouTube channel below!
Carbonwurks has been working with Quicksilver Exhausts for a solid 5+ years now and our relationship has gone from strengths to strengths. Pretty much every one of our development cars has featured one of their systems and there is a good reason why, they are the masters of making some of the finest exhaust systems money can buy!
Our latest development car is the BMW G82 M4 Competition. This car has undergone a complete upgrade on the carbon side with a whole host of M Performance style parts designed and produced by ourselves.
BMW offer an M Performance exhaust and diffuser which creates a very unique looking back end that is almost a bit Lexus LFA inspired. Carbonwurks & Quicksilver has set out to better the pretty ordinary sounding M Performance exhaust BMW offer and over the course of 6 months worth of development, we collectively offer a fantastic diffuser and exhaust option for those wanting that M Performance style.
Carbonwurks produce the diffuser which includes 3 parts all in 100% full prepreg autoclave carbon fibre. The main carbon diffuser is coupled with a carbon exhaust trim surround which is different to the OEM BMW version which is a standard black metal. To finish the look we also offer a tow hook cover to give a seamless finish. Various bolts, rivnuts and brackets are included for an easy OEM level of fitment.
Quicksilver have produced the exhaust in two parts: OPF-Back – for owners wanting to keep their car emissions friendly; and with optional OPF & Secondary Cat Delete pipes (supplied with pre-programmed terminator connectors so the vehicle does not require remapping, with the ability to revert back to stock without a trace).
As you may or may not know, here at Carbonwurks we are a bit track orientated and inspired! When we are not producing or repairing carbon parts, we are either talking about race cars or going out on track in race cars!
One area of Carbonwurks is the track and race background. We originally were founded off the back of racing and the fascination with the material that is carbon fibre. We have been in the motorsport industry since the early 2000’s and have gained a wealth of knowledge and experience that money just can’t buy.
One of our test & development vehicles is a Renault Clio 200 RS which started it’s life off as an honest hot hatch which quickly with a bit of spec creep, has become quite a track weapon. The Clio has been completely stripped out, the shell and chassis substantially lightened and has gone through a complete nut and bolt restoration where every part has either been upgraded or refurbished where possible.
Carbonwurks is working on a motorsport division along with obtaining more knowledge with aerodynamics and testing procedures that, further helps us develop our carbon fibre products for road and track cars.
With our Clio not being overly road compliant, we trailered the car up from sunny Bournemouth to not so sunny Donington Park. The shake down included various runs honing in the 3 way adjustable Nitron Suspension as well as bedding in a new drivetrain and braking system. To help us dial the suspension in we brought along our resident front wheel drive racing specialist Alex Morgan who not only has won races and fought for the Clio Cup UK championship title but currently races in the TCR championship as well.
Throughout the day we tweaked the tyres pressures to find their perfect operating temperature getting a great temperature spread over the entire tyre. The suspension was easy to adjust both with slow and fast bump & rebound that helped with consistency in the balance of the car. The Clio has just shy of 300BHP (at time of writing) with help from a Rotrex supercharger. With ramping up the power to 50% more than it rolled out the factory, having the right amount of cooling is crucial not only for the engine but the supercharger unit itself.
As briefly touched on, we test methods out on the Clio to further discover the best way to obtain load pressures on aerodynamical components. Along with load pressures we stress test with shock and frequencies that a car may encounter which would potentially cause wear or failure of parts.
After a long day on track, the only fault was the differential which had a sense of humour failure 30 minutes from the end of the day. We gained more experience with this particular development car both with the handling and performance aspects as well as our testing procedures.
Quick update! Since we wrote this blog we’ve had the car wrapped and added a few more tasty extras!
When you think of carbon fibre, you’ll likely associate the name/wording with the automotive or aerospace industry. Carbon however makes up around 18% of the human body and is the 2nd biggest element that makes us who we are!
You may be thinking at this point, why is Carbonwurks talking about how I’m made? The answer is quite simple, each carbon fibre part is uniquely different and no 2 parts can ever be identical, much like ourselves.
Although a carbon fibre part from a little distance away can look the exactly the same as another, there are many reason why it wouldn’t do. With carbon fibre parts always being hand made (even in the most automated of manufacturing plants), there are always slightly differences that make each part completely unique.
When producing carbon fibre, Carbonwurks will always endeavour to make each and every part as high quality as possible and to ensure each part fits and looks as best as physically possible. It is however impossible to produce a completely flawless part with zero weave movement, a 100% flat finish or a perfect join for components that are made with a split mould (the vast majority of any carbon parts produced to date).
At first, for those who may be incredibly particular and have laser beam sight, you may think that this sounds like a bad thing but on the contrary! Knowing that the part on your car is not like anyone else’s makes it unique and with that, special.
For sure having a part with terrible weave distortion, a lacquer finish that resembles the surface of the moon or a part that won’t fit the car is simply not good enough but having a few individual unique traits is what makes carbon fibre, carbon fibre.
Each carbon fibre part will tell a tale of the person and people who made it. Each person will have a slightly different technique and whether that be in the layup, trimming or finishing of a part you are going to have something that has it’s own DNA.
A little bit of insight in this blog post as to carbon fibre production with each part having it’s own unique identity and remember, you are nearly 1/5th the same as a carbon fibre part (well sort of)!…
Over the past few months we have been working on the Carbonwurks M-Performance Carbon Fibre Components for the BMW M3 & M4 G8X series.
It’s well known the BMW M-Performance upgrades are some of the best available out there in terms of quality and finish. They also look pretty decent on the car once fitted. The only issue with these upgrades is that they are ridiculously expensive.
With a standard M4 Competition costing around £76,000 you’re then looking at an additional £4000 plus for the M Carbon Exterior Styling Pack which only offers a boot lid spoiler, mirror caps, inlets and rear diffuser in Carbon.
If you want the full M-Performance pack then not only is this an after factory build extra but it’s going to set you back an additional tasty £7000 – £8000 (Not including the exhaust). At the time of writing, certain parts of the full M-Performance pack aren’t actually available to purchase from their accessories configurator.
We’re now offering a full suite of Carbonwurks M-Performance style carbon fibre parts for the M3 G80 and M4 G82 & G83 in one easy pack (Or separate parts if you want to build it up in stages) that’s more cost effective without compromising on quality.
Our aero parts; the 3-piece front splitter, canards, rear diffuser, rear wing and side skirt extensions add an aggressive / GT4 style to the exterior of vehicle which can then be further upgraded with rear winglets, side breathers and fuel cap!
We have also brought in some complimentary Genuine BMW products to round off the M-Performance in the form of interior upgrades such as the Alcantara armrest, Alcantara knee pads, carbon side sills and a few other little extras!
We’ve linked up with MST Performance for an impressive air intake system and Downstar Inc over in the US for their pretty special engine bolt dress up kit to really make your M3 / M4 stand-out from the crowd.
Unlike others we’ve fully fitted all our parts and tested them to the extreme at Silverstone Race Circuit here in the UK. We’re able to stand-by the quality, fitment and final look of our carbon fibre products for all this very reason.
Our background is a little unlike others. We originated from a Motorsport background and even from a very early stage, we set out to produce and sell high-end, performance carbon fibre parts that will stand the test of time. To do this, we had to make sure that these components are not only designed to look great but can also cope with the day to day grind that a car endures as well as strenuous track usage for those owners wanting to push the limits of their car (and perhaps their ability!).
As part of the development programme we run with our components, we test our development cars on track and runways to ensure stability of the parts themselves and to take all important data that can further improve production methods and means of making our products.
Recently we signed off our BMW M3 / M4 G8X programme by testing our development M4 on track at Silverstone circuit. The day was shared with Quicksilver Exhausts who are a long standing partner company that we invited along to help get as much data as possible with an exhaust system being made for a diffuser designed by ourselves.
The testing day at Silverstone entailed various high speed runs not only pushing the cars top speed to check for deformation and stability of the parts but, to also run the car aggressively over rumble strips and kerbs to ensure the parts would be suitable to various violent frequencies that a car can experience. The exhaust system was monitored for heat expansion and tolerances which without doing so and obtaining crucial data may have adverse longevity effects, particularly for those driving in a spirited fashion.
When considering and choosing a company to purchase parts from, one of the key questions should always be “Have these parts been tested and are they safe?” At Carbonwurks we will always endeavour to put in enough research and development time into our product range to give the highest quality product at an affordable price point.
With over 20 years of motorsport experience both on and off the track, we know the demands and requirements of components and will continue to strive for perfection.
A short video of our trip to Silverstone can be found on our Youtube channel, link is below.
Here at Carbonwurks we’ve always said that we’re different from the rest when it comes to our Carbon Fibre products.
We’re proud that we don’t import products and instantly ship to the masses unlike a lot of others in the market. Carbonwurks is much more than this as we offer in house; full fabrication, manufacturing, skinning and repair work of carbon fibre components.
To set ourselves apart from the rest we applied to become part of “Made In Britain” which is an accreditation in its own right to show we offer production right here in the UK. The mark itself lets our customers know that we are a trusted company that values transparency, sustainability and ethical business practices.
There will be some products that we still import from outside of the UK (MST Performance, FI Exhausts and various other partner brands) for various product lines that we offer in which case the mark won’t be used against them. This is further to re-enforce our main value of transparency.
As part of the application process we have to show / prove to the Made In Britain Team that we either fully manufacture parts in house or that other products undergo a substantial change / transformation at our HQ here in Bournemouth, Dorset.
We’re delighted to announce that we were successful in our application and now have the right to proudly display the Made In Britain mark on our website and join over 1200 other British Manufacturers in doing so.
We don’t often post up about the background less exciting work we do however, this time around we thought it might be a nice little read.
Although we don’t repair a massive amount of carbon it’s something we can offer. Depending on how bad the damage is it sometimes is more expensive to repair than to buy a new replacement part, it also depends on application whether it’s also safe to do so. A Jaguar diffuser came our way recently that is nearly £1,400 to buy new and due to the relatively minor damage it made sense to repair. This repair however was done to the customers budget and being a cosmetic part rather than structural, we opted for a simple wet lay method rather than a vacuum bagging technique.
The diffuser had a fight with a tree stump and unfortunately lost the battle. Part of the lower diffuser had broken along with being deformed. The side bolt positions also had fratured along with the top venturi sections having stress fractures too. This diffuser had also previously been repaired which needed some further refinement.
The first steps were to strip the old cracked resin and lacquer back down to the carbon, probably one of the hardest parts to get right. Go too hard and the carbon comes away, too little and you will always see the cracked and cloudy resin underneath the repair. Once the area has been taken back it’s time to rebuild. The reverse of the diffuser is re-build with a carbon matting and resin mix which is cost effective and yet will give the diffuser a lot more strength.
With the reverse of the part being built up and properly shaped the cosmetic side can start to come together with new twill carbon being laid over. This involves a wetting coat of resin which needs several applications over days with curing time in-between. The side bolt positions are also reinforced at this point with metal spacers being installed and bonded in place before carbon being laid.
With more coats of resin, trimming and flatting in between the carbon starts to form properly. The final part of the repair is completely stripping the old lacquer down, making sure the surface is flat and uniform, the holes at this point are reformed to the original OEM measurements. It’s now time for lacquer.
Once the part has been lacquered the part is then further refined with wet sanding and a course of polishing to bring a super high gloss and smooth finish. Weeks of work involved but bringing an old battered carbon back from the brink is definitely worth it!
Have a look below for the repair process photo gallery.
At Carbonwurks we are always working on expanding our products range, our ethos is “Only offer the best available. If not available, then produce the best”. Carbonwurks now are stocking all of Arma Speed parts which range from their beautifully engineered full carbon intake kits to their carbon body accessories and brake systems.
For 1 week only and to celebrate our partnership we are offering discounted prices on their parts. After the 1 week is up, we will be selling their parts for normal retail.
Make use of this 1 time offer and get in touch at firstname.lastname@example.org with details of your car and we will let you know what price we can do. We ship anywhere in the world.