What do YOU use to make/machine your body/chassis plugs?

[Jersey Tom]

This year we are looking to CNC machine our body plugs. The past year we had used 2" foam from Home Depot, cut out sections kinda ghetto using acrylic cross-section guides, hot wire and glued the sections together. Works allright. I'd rather machine it though, just for accuracy, repeatability, and the ability to do much more complex geometry.

So what do you guys do? Any foam in particular you use? On what type/size machine?

[Jersey Tom]

This year we are looking to CNC machine our body plugs. The past year we had used 2" foam from Home Depot, cut out sections kinda ghetto using acrylic cross-section guides, hot wire and glued the sections together. Works allright. I'd rather machine it though, just for accuracy, repeatability, and the ability to do much more complex geometry.

So what do you guys do? Any foam in particular you use? On what type/size machine?

[olsen5]

We luckily found a sponsor that was willing to donate the use of his large 3 - axis CNC machine to mill our body plug, he did ask for us to pay for the material though which was a low density tooling foam. It took a lot of work filling in the pockets between the foam grains but our body did turn out pretty good with some tricky geometries.

[RiNaZ]

We used the same styrofoam from home depot too. Works good but i think MDF board is a lot better, but will be heavy. And it takes longer than styrofoam.

we used KOMO 3 axis milling machine.

[Erich Ohlde]

If you are going to be using a foam you want to use a CNC Router not a mill. The router will generally run 10-13k spindle rpm, this will allow for better finish and quicker run time. We use a high density foam for our chassis bucs, but we have to bake it so the blue or pink foam from homedepot would not work.

[Jersey Tom]

Most good CNC mills these days come with 12000-15000 spindles. Sadly, we don't have quite that good of a CNC mill! Or any router.. that I know of.

Would be a good part for a Bridgeport HSC. 40000rpm spindle. Ridiculous.

[Erich Ohlde]

Holy shit! didn't know they spun them that fast

[KU_Racing]

we had our body plug cnc cut last year. We used a block made from 2" thick sections of mdf- worked beautiful, great surface, and the mold is very heavy and stiff, which makes it east to prep and seperate. One word of caution though- if the company doing the work does not have a mill capable of cutting everything in one setup (the mill we used didnt have enough z travel, so the mold was cut in 2 pieces) make sure that they will be able to accurately maching the second half- dowel holes in the mold is a good way to do this.

[Homemade WRX]

years past we did wood guided (similar to your acrylic) home insulation foam...did it all by hand.
this year our windtunnel has a new cnc that we have permission to use, being I work there.
the cool bit is it has a 4'wide x 8' long and 20" tall cutting range...so very few pieces http://fsae.com/groupee_common/emoticons/icon_biggrin.gif

[Ian McMurdo]

There has been a lot of construction in recent years on our campus, so 'aquiring' foam has become somewhat of a tradition. I would like to do it out of mdf in the future though, because foam is a pain to work with. I would imagine that that much MDF would be quite expensive though. Any comments from teams that have done it?

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