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Lightweight Construction in Perfection

19 April 2016

Lightweight Construction in Perfection

The Callaway Competition Corvette C7 GT3-R is ready for the new racing season – packed with power, yet still lightweight.

RAMPF explains that the car will turn heads thanks to both fast lap times and its pioneering design. RAKU-TOOL board and liquid materials specially developed for the composites industry by RAMPF Tooling Solutions have also played their part in this.

“This is the most beautiful car we have ever built,” say Giovanni Ciccone and Ernst Wöhr, Owners of Callaway Competition. “There is certainly no denying it – the new Corvette C7 GT3-R from the company based in Leingarten in the Baden-Württemberg region of Germany is a real feast for the eyes. It exudes power, but also boasts elegant contours and sophisticated aerodynamics. And everywhere there is carbon.”

RAMPF adds that the Callaway Competition has been racing for over 25 years, and is the longest-serving team in the ADAC GT Masters, the prestigious race series for GT3-class sports cars. There has never been a race in this series without a Callaway Corvette on the grid – with 23 race wins; the Callaway Corvette Z06.R GT3 is the most successful racing car in the history of the ADAC GT Masters.

According to RAMPF, for the new Corvette C7 GT3-R, however, only the chassis and the up to 600 HP, water-cooled, 6.2-liter V8 engine were taken from the series model. The development of the vehicle – done completely in-house – began with the design of the technically-relevant parts in CAD in mid-2014. The vehicle design was finalised by the end of the year, and construction began in Leingarten, Germany in spring 2015.

The moulds for the racing car were milled directly using the CAD data. RAMPF says it delivered high-quality RAKU-TOOL board materials that were used to create moulds for producing various lightweight parts for the C7 GT3-R. RAKU-TOOL resin infusion was used for those parts that were not manufactured in prepreg. It says:

  1. The brake air duct was manufactured using moulds made from the RAKU-TOOL WB-1404 working board material. The epoxy infusion system RAKU-TOOL EI-2500 / EH-2970 was used in the production of the carbon- parts.

  2. The central console was manufactured using moulds made from the RAKU-TOOL WB-0700 epoxy working board material.

  3. The outer door panel was manufactured using moulds made from the RAKU-TOOL WB-0801 working board material.

  4. The rear fender was manufactured using moulds made from the RAKU-TOOL MB-0600 modelling board material.

  5. The front fender was manufactured using moulds made from the RAKU-TOOL WB-1404 working board material and the RAKU-TOOL WB-0600 modelling board material.

“RAKU-TOOL WB-0691 and WB-0700 are particularly suited for lay-up tools, vacuum forming moulds, and for processing prepregs,” explains Marcus Vohrer, Head of Application Engineering at RAMPF Tooling Solutions. “RAKU-TOOL WB-1404 moulds were used to manufacture carbon parts with EI-2500 / EH-2970 resin infusion. The benefits this provides are an outstanding surface on the resin-infusion parts, excellent fit accuracies, and no damage to the moulds during demoulding.”

Without a doubt, the new Corvette C7 GT3-R is a masterpiece. “As a private team, projects such as this present a particular challenge, as we cannot call on the financial and staffing resources of a large automobile plant. However, thanks to the tireless efforts of our staff and technology partners, we have been able to finish the vehicle in a comparatively short space of time,” says Wöhr.

Incidentally, it is not only racing enthusiasts in Germany who will have the pleasure of seeing the C7 GT3-R in action on the track. RAMPF says the car meets the specifications and safety requirements of the FIA, the world governing body for automobiles and motor sport, and can therefore be used in races around the world.


Photo provided by Rampf




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