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CLR Project Leichtbau: adding lightness to the tune of 250kg

Seats prob save 40kg, Ti exhaust, Voltphreaks Li battery, no spare or tool kit, those are the biggies
 
I want a pretty stock look and have gone for free mods:
Beams, front and rear
Rear sub woofer and door speakers (all heavy)
Rear seats
All the boot crap
45 Amp/hr battery lying around, which is much lighter and works fine.

Perhaps 60kg lost, but it still feels heavy compared to my old C4 :nooo:

The rear exhaust on the turbo and NA are both very heavy. That's the next area to tackle.
 
Possibly a daft question: are the front and rear impact beams not rather important in the event of an impact??!
 
jinjaninja said:
Possibly a daft question: are the front and rear impact beams not rather important in the event of an impact??!

Dont crash
 
A few more bits and pieces done today. As I want to work out what level of compromise is acceptable I have decided to remove the insulation/sound-proofing/carpets in stages. Reason being I don't want to end up with some rattling tin can (race-car). So first I have removed the removable insulation behind the rear side panels and lower panel behind rear screen. Also removed the wiper motor as I have ordered a painted plug to fill the hole.
For info here are the weights I removed (Total today 11.8kg):
Wiper motor assembly (includes insulation behind rear panel): 2.2kg
The 2 carpets behind the rear seats: 6kg
Removable insulation behind rear side panels: 1.8kg per side (3.6kg total)

Whilst there I also weighed a few other components:
Rear side lower panel: 1.6kg
Rear wiper motor cover panel: 0.5kg
1x speaker: 0.6kg
Just to clarify here are pictures for reference:
Rear wiper motor cover (also insulation that I removed):
Project%20Lightening%201_zpsrbh1hr0r.jpg

Wiper motor removed
Project%20Lightening%202_zpsd4tjv6uh.jpg

So this little lot is 2.2kg
Project%20Lightening%203_zps3gfccxcd.jpg

2x rear carpets removed, 6.0kg for these; you can also see the 2x sound deadening sheets in this picture (not removed yet):
Project%20Lightening%204_zpspufqllhu.jpg

Project%20Lightening%2012_zpszkeugbym.jpg

Rear side panel insulation 1.8kg (I didn't remove the stuck on material behind the speaker)
Project%20Lightening%205_zpspnd1cles.jpg

Project%20Lightening%206_zps4huwgdcp.jpg

Project%20Lightening%207_zpsueyyzylc.jpg

Project%20Lightening%2011_zpsavbjiqhg.jpg

The rear side panel is 1.5kg and wiper motor cover 0.5kg:
Project%20Lightening%208_zpstgr0bfce.jpg

Project%20Lightening%2010_zpsqupmjyub.jpg

I aim to cover all the areas where carpets have been removed with lightweight alcantara. I refitted all the panels, so to all intents and purposes it still looks stock. I tested the Hifi at the current stage and there were no perceptible rattles etc. No test drive yet...
 
I know where there are some carbon side panels dude, weigh nothing !!!!! 8)
 
JohnnyDangerous said:
jinjaninja said:
Possibly a daft question: are the front and rear impact beams not rather important in the event of an impact??!

Dont crash

Not really; they are light alloy so are really only there to prevent serious chassis/engine damage in a light collision. They will not absorb that much force to have any effect in terms of a life threatening crash.
 
ELA said:
JohnnyDangerous said:
jinjaninja said:
Possibly a daft question: are the front and rear impact beams not rather important in the event of an impact??!

Dont crash

Not really; they are light alloy so are really only there to prevent serious chassis/engine damage in a light collision. They will not absorb that much force to have any effect in terms of a life threatening crash.

Exactly that I believe its to stop the bumpers deforming in a 5mph impact.
 
JohnnyDangerous said:
I know where there are some carbon side panels dude, weigh nothing !!!!! 8)

But cost a fortune :wink: For the likely 1kg max they may save per side I think there may be more cost effective parts to try before getting that serious.
First off I want to see what can be done for free.

After this then (in the following order):
LWFW
Carbon seats
Polycarbonate windows
Carbon roof
Light alloys
Light brakes
Lightweight battery
 
Do you have a sunroof? If not I would not bother with carbon roof, My mate has the panels will prob be cheap, I get a good discount with voltphreaks and on the GT carbon seats if you want it its yours.
 
You do realise that theres a GT3 for sale for £50k dont you on here
 
kingston said:
You do realise that theres a GT3 for sale for £50k dont you on here

He already has a GT3 :wink:
 
JohnnyDangerous said:
kingston said:
You do realise that theres a GT3 for sale for £50k dont you on here

He already has a GT3 :wink:

Kingston, as Johnny says; I already have an GT3, this project is solely for what can be achieved with the Carrera.

JD: My car does indeed have a sunroof hence me looking at the carbon roof option. I'd be very much interested in knowing what sort of prices all these bits are likely cost in the future :thumb:

Went for a test drive today and I was quite impressed with the harmonics. I would say only around 5-10% increase in road noise thus far. Based on this I decided to remove the rear sound deadening in the rear. Bit of a pain but a heat gun with plastic scraper does the job. All residue cleaned off with WD40. The 2 small patches came in at 0.8kg.

The real problem is that the surfaces are all undulating with bolts, grommets, channelled grooves... So to lay the alcantara is a bit of a PITA. I decided, as I want as OEM a look as possible, the best option would be to try and level off all the surfaces. So I have been filling in all the channels and removing grommets and re-contouring with Aviation 3M High Speed Tape, re-routing wiring looms... Real time consuming stuff and not helped with the limited space in the back. Anyway getting pretty close to laying the Alcantara now:
Project%20Lightening%2013_zpscgynkfas.jpg

Project%20Lightening%2014_zpsv7koq9gt.jpg

Project%20Lightening%2015_zps2q2weuxr.jpg

Project%20Lightening%2016_zpsgidcwcvh.jpg
 

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