Body panel construction
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Pro
Joined: Jul 2022
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Body panel construction
Working in aerospace, I'm very familiar with composite basics and different types of composite structure.
what type of cross section or laminate build-up is the majority of these panels consist of?
I am familiar with hybrid aramid /foam core and kevlar/aramid fiber lay-ups as well as carbon fiber laminates. Is the C-8 any of these or is it basically fiberglass?
I don't have a C-8 but hopefully I'll get one next year, thanks.
what type of cross section or laminate build-up is the majority of these panels consist of?
I am familiar with hybrid aramid /foam core and kevlar/aramid fiber lay-ups as well as carbon fiber laminates. Is the C-8 any of these or is it basically fiberglass?
I don't have a C-8 but hopefully I'll get one next year, thanks.
Le Mans Master
Joined: Sep 2012
Posts: 7,146
Likes: 1,940
From: Hagerstown MD
St. Jude Donor '15-'16,'18
Not fiberglass.
OK, I stand corrected. It's not the same "fiberglass" that was used in the early Corvettes.
Sounds like it is a combination of several different components.
OK, I stand corrected. It's not the same "fiberglass" that was used in the early Corvettes.
Sounds like it is a combination of several different components.
Last edited by rmorin1249; Oct 23, 2022 at 11:48 AM.
Race Director
Joined: Apr 2017
Posts: 13,602
Likes: 12,864
From: Virginia
Working in aerospace, I'm very familiar with composite basics and different types of composite structure.
what type of cross section or laminate build-up is the majority of these panels consist of?
I am familiar with hybrid aramid /foam core and kevlar/aramid fiber lay-ups as well as carbon fiber laminates. Is the C-8 any of these or is it basically fiberglass?
I don't have a C-8 but hopefully I'll get one next year, thanks.
what type of cross section or laminate build-up is the majority of these panels consist of?
I am familiar with hybrid aramid /foam core and kevlar/aramid fiber lay-ups as well as carbon fiber laminates. Is the C-8 any of these or is it basically fiberglass?
I don't have a C-8 but hopefully I'll get one next year, thanks.
Drifting
Joined: Sep 2000
Posts: 1,888
Likes: 230
From: Livingston County, Michigan
The majority of the body panels are made by a company called Continental Structural Plastics. As mentioned above, it is a SMC format, using E glass fiber. Uniqueness to the formulation is the usage of glass microspheres as one of the fillers. CSP’s tradename for this is TCA UltraLite.
Some of the “structural” bits are supplied by Molded Fiber Glass, which has been a supplier to Corvette since the very first model. The frunk tub is a low density SMC that they call “float SMC” due to its 0.9 specific gravity. The rear surround is especially interesting because the main panel is a carbon/glass hybrid SMC while the bulkhead is a high density SMC (for cabin noise reduction reasons), then bonded together.
The exposed weave is a 3k twill. The resin has a very slight purple tint to it, for aesthetics.
I’ve been fortunate enough to work for both the glass supplier to CSP and MFG as well as the carbon supplier to the multiple processors for Corvette over the years. Interesting stuff, but not nearly as “cool” as aerospace or high end formula cars.
Some of the “structural” bits are supplied by Molded Fiber Glass, which has been a supplier to Corvette since the very first model. The frunk tub is a low density SMC that they call “float SMC” due to its 0.9 specific gravity. The rear surround is especially interesting because the main panel is a carbon/glass hybrid SMC while the bulkhead is a high density SMC (for cabin noise reduction reasons), then bonded together.
The exposed weave is a 3k twill. The resin has a very slight purple tint to it, for aesthetics.
I’ve been fortunate enough to work for both the glass supplier to CSP and MFG as well as the carbon supplier to the multiple processors for Corvette over the years. Interesting stuff, but not nearly as “cool” as aerospace or high end formula cars.
Last edited by acrace; Dec 20, 2022 at 04:34 PM.
Drifting
Joined: Sep 2000
Posts: 1,888
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From: Livingston County, Michigan
Melting Slicks
Joined: May 2021
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Arguing over semantics mostly. It is E glass fibers, mixed with resin, etc. The method of manufacture is different from what some would call "fiberglass". If you see someone blowing fiber glass onto a mold, that is a very different process often used to make larger structures, boats, etc. and it is usually a lot thicker. My PWC has a blow molded fiberglass hull.
SMC is all molded together from what I have read.
I saw a C5 that was involved in a house fire. Somehow the back end of the C5 burned to the ground (it was parked just outside the garage), and the front end was fine. It was amazing all the burnt glass fibers all over the place. Everything was totally melted up to the firewall. Engine looked good though. I offered the homeowner $5k and I would haul it off. He agreed, shook hands and I ran off to the bank. Came back with $5k and someone else was there writing him a check for more than we had agreed. I was rather pissed... My lesson learned was I should have asked him to come to the bank with me, you know, to help count the moola.
SMC is all molded together from what I have read.
I saw a C5 that was involved in a house fire. Somehow the back end of the C5 burned to the ground (it was parked just outside the garage), and the front end was fine. It was amazing all the burnt glass fibers all over the place. Everything was totally melted up to the firewall. Engine looked good though. I offered the homeowner $5k and I would haul it off. He agreed, shook hands and I ran off to the bank. Came back with $5k and someone else was there writing him a check for more than we had agreed. I was rather pissed... My lesson learned was I should have asked him to come to the bank with me, you know, to help count the moola.
Racer
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Drifting
Joined: Sep 2020
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From: Columbia SC
This info is great!!! I'm also in (was) the Aerospace Composites business ( Retired). Always wondered if they used E Glass or S Glass. Chevy touts that the deck lid is Carbon.. but I knew it was a Hybrid of glass and just a little Carbon fibers.
During my 30+yrs in the composite industry I have worked with many different types of FRP .... except for SMC. I assume all of the panels are press molded, Bladder molded or is there some autoclave process use too?
During my 30+yrs in the composite industry I have worked with many different types of FRP .... except for SMC. I assume all of the panels are press molded, Bladder molded or is there some autoclave process use too?
Drifting
Joined: Sep 2000
Posts: 1,888
Likes: 230
From: Livingston County, Michigan
This info is great!!! I'm also in (was) the Aerospace Composites business ( Retired). Always wondered if they used E Glass or S Glass. Chevy touts that the deck lid is Carbon.. but I knew it was a Hybrid of glass and just a little Carbon fibers.
During my 30+yrs in the composite industry I have worked with many different types of FRP .... except for SMC. I assume all of the panels are press molded, Bladder molded or is there some autoclave process use too?
During my 30+yrs in the composite industry I have worked with many different types of FRP .... except for SMC. I assume all of the panels are press molded, Bladder molded or is there some autoclave process use too?
S-glass is too expensive for volume automotive applications. I did some work on continuous S-glass manufacturing (as opposed to the batch process) but it was used primarily for composite armor and some injection molding thermoplastic reinforcement.
Drifting
Joined: Sep 2020
Posts: 1,423
Likes: 639
From: Columbia SC
OMG Those are big *** presses... I did some work with MFG in Aberdeen South Dakota making Wind Turbine blades with Epoxy / Glass resin transfer process. 40 and 52 meter long blades ~ 8000lbs each. Sorry to say that facility is closed now.
E-Ray, 3LZ, ZER, LIFT
Joined: Sep 2007
Posts: 34,950
Likes: 12,363
From: NE South Carolina
Working in aerospace, I'm very familiar with composite basics and different types of composite structure.
what type of cross section or laminate build-up is the majority of these panels consist of?
I am familiar with hybrid aramid /foam core and kevlar/aramid fiber lay-ups as well as carbon fiber laminates. Is the C-8 any of these or is it basically fiberglass?
I don't have a C-8 but hopefully I'll get one next year, thanks.
what type of cross section or laminate build-up is the majority of these panels consist of?
I am familiar with hybrid aramid /foam core and kevlar/aramid fiber lay-ups as well as carbon fiber laminates. Is the C-8 any of these or is it basically fiberglass?
I don't have a C-8 but hopefully I'll get one next year, thanks.
The majority of the body panels are made by a company called Continental Structural Plastics. As mentioned above, it is a SMC format, using E glass fiber. Uniqueness to the formulation is the usage of glass microspheres as one of the fillers. CSP’s tradename for this is TCA UltraLite.
Some of the “structural” bits are supplied by Molded Fiber Glass, which has been a supplier to Corvette since the very first model. The frunk tub is a low density SMC that they call “float SMC” due to its 0.9 specific gravity. The rear surround is especially interesting because the main panel is a carbon/glass hybrid SMC while the bulkhead is a high density SMC (for cabin noise reduction reasons), then bonded together.
The exposed weave is a 3k twill. The resin has a very slight purple tint to it, for aesthetics.
I’ve been fortunate enough to work for both the glass supplier to CSP and MFG as well as the carbon supplier to the multiple processors for Corvette over the years. Interesting stuff, but not nearly as “cool” as aerospace or high end formula cars.
Some of the “structural” bits are supplied by Molded Fiber Glass, which has been a supplier to Corvette since the very first model. The frunk tub is a low density SMC that they call “float SMC” due to its 0.9 specific gravity. The rear surround is especially interesting because the main panel is a carbon/glass hybrid SMC while the bulkhead is a high density SMC (for cabin noise reduction reasons), then bonded together.
The exposed weave is a 3k twill. The resin has a very slight purple tint to it, for aesthetics.
I’ve been fortunate enough to work for both the glass supplier to CSP and MFG as well as the carbon supplier to the multiple processors for Corvette over the years. Interesting stuff, but not nearly as “cool” as aerospace or high end formula cars.
As noted the fellow that convinced GM to use fiberglass was Bob Morison owner of Molded Fiberglass. My brother-in-law is visiting and recalls riding in one of the 1st 1953 Corvettes Mr. Morison owned! He lived on the same street in Ashtabula OH. He said he was ~10 at the time and several kids went for a short ride. I managed an R&D Lab in Ashtabula OH for Linde in the mid 1970s.
As noted they no longer supply the less expensive body panels only some of the more special higher value products like the trunk that floats in water!
Last edited by JerryU; Oct 23, 2022 at 12:21 PM.
Race Director
Joined: Aug 2016
Posts: 12,769
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From: Garden Valley CA
An older article that stops at the C6 but it is an interesting read about the progression of Corvette SMC body materials:
https://www.motortrend.com/how-to/ve...ody-materials/
https://www.motortrend.com/how-to/ve...ody-materials/
3rd Gear
Joined: Mar 2026
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Arguing over semantics mostly. It is E glass fibers, mixed with resin, etc. The method of manufacture is different from what some would call "fiberglass". If you see someone blowing fiber glass onto a mold, that is a very different process often used to make larger structures, boats, etc. and it is usually a lot thicker. My PWC has a blow molded fiberglass hull.
SMC is all molded together from what I have read.
I saw a C5 that was involved in a house fire. Somehow the back end of the C5 burned to the ground (it was parked just outside the garage), and the front end was fine. It was amazing all the burnt glass fibers all over the place. Everything was totally melted up to the firewall. Engine looked good though. I offered the homeowner $5k and I would haul it off. He agreed, shook hands and I ran off to the bank. Came back with $5k and someone else was there writing him a check Home Builders for more than we had agreed. I was rather pissed... My lesson learned was I should have asked him to come to the bank with me, you know, to help count the moola.
SMC is all molded together from what I have read.
I saw a C5 that was involved in a house fire. Somehow the back end of the C5 burned to the ground (it was parked just outside the garage), and the front end was fine. It was amazing all the burnt glass fibers all over the place. Everything was totally melted up to the firewall. Engine looked good though. I offered the homeowner $5k and I would haul it off. He agreed, shook hands and I ran off to the bank. Came back with $5k and someone else was there writing him a check Home Builders for more than we had agreed. I was rather pissed... My lesson learned was I should have asked him to come to the bank with me, you know, to help count the moola.
3rd Gear
Joined: Mar 2026
Posts: 3
Likes: 0
The majority of the body panels are made by a company called Continental Structural Plastics. As mentioned above, it is a SMC format, using E glass fiber. Uniqueness to the formulation is the usage of glass microspheres as one of the fillers. CSP’s tradename for this is TCA UltraLite.
Some of the “structural” bits are supplied by Molded Fiber Glass, which has been a supplier to Corvette since the very first model. The frunk tub is a low density SMC that they call “float SMC” due to its 0.9 specific gravity. The rear surround is especially interesting Construction Estimating Services because the main panel is a carbon/glass hybrid SMC while the bulkhead is a high density SMC (for cabin noise reduction reasons), then bonded together.
The exposed weave is a 3k twill. The resin has a very slight purple tint to it, for aesthetics.
I’ve been fortunate enough to work for both the glass supplier to CSP and MFG as well as the carbon supplier to the multiple processors for Corvette over the years. Interesting stuff, but not nearly as “cool” as aerospace or high end formula cars.
Some of the “structural” bits are supplied by Molded Fiber Glass, which has been a supplier to Corvette since the very first model. The frunk tub is a low density SMC that they call “float SMC” due to its 0.9 specific gravity. The rear surround is especially interesting Construction Estimating Services because the main panel is a carbon/glass hybrid SMC while the bulkhead is a high density SMC (for cabin noise reduction reasons), then bonded together.
The exposed weave is a 3k twill. The resin has a very slight purple tint to it, for aesthetics.
I’ve been fortunate enough to work for both the glass supplier to CSP and MFG as well as the carbon supplier to the multiple processors for Corvette over the years. Interesting stuff, but not nearly as “cool” as aerospace or high end formula cars.