Building a Rear Wing with Carbon Fibre and Nomex

Further information and links ▼

In this step-by-step video tutorial we demonstrate a method of making high performance carbon fibre downforce/aero wings for motorsport without needing a mould. Instead, carbon fibre is laminated onto the outside of an XPS foam core which has been profiled using a hotwire cutter. Mylar is used to smooth the carbon fibre and a vacuum bag is used for consolidation. End plates, which include aluminium mounting inserts, are made using Nomex honeycomb bonded to carbon fibre sheet.

00:00 - Introduction
01:37 - Hotwire cutting XPS foam core
04:05 - Machining wing inserts
05:21 - Cutting Mylar surface film
06:14 - Prepare the vacuum bag
06:31 - Preparing the carbon reinforcement
07:33 - Wet-out reinforcement with epoxy
09:18 - Wrapping the carbon fibre around the foam core
11:22 - Machining the carbon sheet for the end plates
13:06 - Aluminium inserts for the end plates
14:56 - Cutting and bonding Nomex honeycomb
18:09 - Filling the edge of the honeycomb panel
18:36 - Assembling the finished wing

For further information, including links to all products used in the tutorial, see the tutorial's project page on the Easy Composites website:

Full Project Details

[Spekulantoss]

Guys, I dont know if you understand the impact of this video. You have basically revealed the secret of how to make decent wings for all formula student teams. As somebody who has been developing the method for my team, this is both blessing and a curse. Through hours of research I have basically settled on a process almost just like this. And now the effort seems pointless. I have also figured out mylar is the magic ingredient, but I could not find a supplier who would be selling it by metre in the full width. And BOOM! Easycomposites now sell it, in the same spec as I have seen elsewhere, only they also let you buy per metre. Another thing are the endplates... again, basically the same process. I love you, and I hate you at the same time 😂

[navigas]

The effort, time and dedication you put into these videos have made my BSc thesis into an A+, it makes me want to improve almost everything around me and it have made you a lifelong customer and me as an (free of charge) ambassador for my fellow interested DIY'ers. Thank you Easy Composites - and especially you Paul.

[OfficiallySnek]

Definitely make the video on molded wings! The information you provide is extremely useful to many people out there

[anthony]

This youtube channel is a legend for teaching every carguys dream parts,

ShoutOut from the Philippines 🇵🇭

[tommylongman]

This is almost identical in every way to how we've made wings in formula student. Very cool to see that the method is something easycomposites think is good enough to share as well!
I'm super impressed with how nicely yours came out. If only ours were as nice every time 😂

[CYMotorsport]

EDIT: 6:50 i've been using different weaves in different applications across many use cases for years. for some reason, i've never even thought to try this. wow.

Need to make this replica for my sim rig! brilliant, as per

[MeatPez]

I cannot believe you give years worth of research and work for free in an easily digestible video. As someone who knows how difficult it can be to teach yourself a very in depth skill with little public info, I applaud you for this.

[vincegarage]

back in 2012 when i thought about making a mould of motorcycle bodyparts, i watch him in the other channel. 11 years later to 2023, when i think about making carbon parts, i still watch him. hahhaha think you are dracula man, no aging at all. your 13++ years of experience make it look so easy to handle all those sticky & itchy things. awesome

[elminz]

Subbed to several hundred channels, yet Easy Composites' tutorials are consistently in the best on any topic. I like the fact that you concisely weigh up pros/cons for alternatives, as well as giving an accurate representation of good real world results, i.e. not perfect, but pretty damn good considering.

[antoniofranklyn]

I enjoy watching content from easy composites. They give me the motivation to do the projects i want to do. Thank you easy composites for making this content and introducing the rest of the world to this skill!

[ChuckThree]

Almost every single video y’all have done for last 2-3 years has been immediately relevant for me. Like, almost concerningly so lol.

Not sure how you know exactly what my next subject matter needs are, but keep at it 😂👍

Thank you Paul and the Easy Comps team!

[mrrustygray]

I feel like I am in composite college when I 2watch these vids, over and over. So much knowledge. Thank you.

[rodrigopena]

Since I joined my Formula Student team, here at Brazil, I've been following Easy Composites channel. I really appreciate the effort you put in to tell us all of this information for free. I wish we could have all the materials and tools you show in the video but we try to achieve the best with what we have. Thank you very much for these informations, especially since I work in the aerodynamics area and we aspire to build a new aerodynamic package for our project.

[SONOBT]

The university I hope to be in next year doesn't have a FS program.

So I hope I can master up enough support to get it going, and this video is a perfect motivator!

[stevesloan]

Your videos are absolutely top shelf.
Its hard to imagine just how many projects have been started, purely thanks to your amazing tutorial videos.
Much love from Australia.

[colewilson]

Just dropping a comment to let you know how much I appreciate these videos. I'm gathering the confidence for a carbon fibre project, and the way the information is presented and explained in all of the Easy Composites videos is just simply incredible. Dispite likely paying for higher shipping costs, my money will absolutely be spent here for anything that is available to get shipped to the US. Thank you!

[flaviovianna]

THE BEST composites content on YouTube. Big Fan! Not a big client yet due to limitations with shipping to NZ, but soon I will be closer.

[SoumilSahu]

Really wish we had this video when I was in Formula Student.

This is an invaluable asset to the motorsports community. I can definitely empathise with the frustration of people who figured all this out themselves, but hey, more competition is always fun!

[seandeterman]

You guys really don't understand how much we all appreciate these videos! So cool and I can't wait to try some of the projects on your channel! Thanks!

[parthghube]

One of the best channels on YouTube!! Thank you Easy Composites