Aluminium Monocoque
Assembly & Manufacture
Assembly & ManufactureHome The aluminium monocoque was produced using a cut-and-fold process, a technique that transforms flat honeycomb sandwich panels into complex 3D structures. Each Larcore A20 panel was CNC-cut…
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Aluminium Monocoque Chassis
Aluminium Monocoque ChassisHome The 2025 chassis was designed as a cut-and-fold aluminium honeycomb monocoque bonded to a steel rear spaceframe. This hybrid structure combined the lightweight stiffness of a monocoque…
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Roll Hoops & Harness Bar
Roll Hoops & Harness BarHome Roll hoops and the harness bar were mounted using reinforced inserts and base plates within the monocoque, designed to meet FSUK rollover protection standards. The…
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Material Testing
Material Testings Home The aluminium honeycomb monocoque was validated against FSUK SES requirements through physical testing. Three-point bending showed panel stiffness above the T45 steel baseline, confirming equivalent flexural performance.…
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Welding & Assembly Fixtures
Welding & Assembly FixturesHome Custom fixtures were built to ensure accuracy during chassis manufacture. The monocoque was folded and bonded in CNC-cut MDF jigs that controlled panel angles within ±0.5°.…
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