Tuned In

146: From Home Builds to Hypercars: Composites for EveryoneComposites might seem like the secret language of aerospace engineers and hypercar builders, but Gabriel Mountjoy from Common Fibers is here to break down those barriers. He’s out to prove that composites aren’t just exotic materials—you can use them to elevate your own builds too. 👉 Use the code ‘PODCAST500’ to get $500 OFF HPA's VIP Package: https://hpcdmy.co/podvip In this episode of Tuned In, Gabe shares his journey from a mechanical engineering student passionate about automotive efficiency to a successful entrepreneur in the composites industry. Alongside his now-wife Ann, he co-invented the first carbon fiber hinge, and today their company is not only one of America’s leading composite manufacturers but also uniquely committed to educating people on how to work with these materials. We explore the evolution of composites in automotive applications, the challenges and opportunities they bring, and why designing for manufacturability is key. Gabe also takes us inside high-profile projects like SSC North America’s Tuatara—a hypercar capable of 300 mph—explaining how they construct mission-critical, complex components such as its carbon-fiber monocoque. Gabe breaks down the essentials of material and resin selection, unpacks layup methods, and clarifies the differences between wet layup, vacuum bagging, and resin infusion. He highlights the advantages of prepreg materials and compares autoclave with out-of-autoclave approaches. Despite producing some of the most intricate composite parts in the U.S., Gabe and his team remain refreshingly open about their processes and deeply passionate about making composites more accessible. 👉 Use the code ‘PODCAST500’ to get $500 OFF HPA's VIP Package: https://hpcdmy.co/podvip Follow Gabe here: Instagram: Commonfibers Facebook: Common Fibers YouTube: Common Fibers WWW: commonfibers.com Timestamps: 0:00 From Home Builds to Hypercars: Composites for Everyone 4:37 Did the passion for cars come first or carbon fiber? 7:54 How do you become a composites engineer? 10:01 What’s your work history prior to starting Common Fibers? 11:18 Are composites much more common in other industries? 14:55 What does Common Fiber’s look like today? 16:11 How are you finding composite technicians? 18:06 Why did you open a second facility? 19:01 Can you briefly explain the different resin types? 21:30 What has been the process of growing a business to have 40 staff? 26:33 How much work are you doing for the aerospace industry? 29:22 What is the SSC North America Tuatara? 30:38 How did you get involved in the hyper car project? 32:30 How does the design and production work with the Tutara parts? 38:01 What’s the benefits of the monocoque over a conventional chassis? 44:11 When we talk about composites, what are the different materials? 47:23 What are the different types of carbon fibre? 49:18 What is carbon's best strength quality? 51:56 How do you validate the strength of your parts? 57:28 What is the process of designing and manufacturing a mold? 1:06:13 How do we layup the carbon or fiber glass into our mold? 1:14:47 What is a wet layup and where would we use it? 1:18:25 What is vacuum bagging? 1:23:02 What is resin infusion? 1:28:43 What is prepreg? 1:38:25 Final 3 questions

345

1T 45min

144: Is a Retired F1 Car the Ultimate Track Toy?Formula 1 represents the pinnacle of motorsport and James Densley along with the team at TDF Limited are breathing new life into retired F1 cars, transforming them back into the ultimate track weapons. 👉 Use the code ‘PODCAST500’ to get $500 OFF HPA's VIP Package: https://hpcdmy.co/podvip James shares his journey from a car-obsessed child through karting to mechanic at the top levels of motorsport. He recounts his experiences in Formula 3 and then with Mercedes F1, before explaining how TDF Limited was founded and started specialising in restoring and supporting retired F1 cars. The conversation explores the complexities involved in purchasing, restoring, and maintaining historic F1 cars, including the challenges posed by obsolete electronics and sourcing rare components. James emphasises the critical role of modern technologies such as 3D scanning in facilitating these restoration projects. We also discuss the operational and logistical challenges of running historic F1 cars today, the development of the TDF One program to make these cars more accessible, and the technical hurdles of modernizing powertrains while preserving the true essence of Formula 1 racing. It’s unfortunate that these extraordinary machines often face the scrap heap or sit around as expensive ornaments after their brief racing lives. What TDF Limited are achieving by resurrecting these masterpieces and returning them to the track is truly groundbreaking. 👉 Use the code ‘PODCAST500’ to get $500 OFF HPA's VIP Package: https://hpcdmy.co/podvip Follow James here: Instagram: @tdf_limited YouTube: @tdflimited WWW: tdf.co.uk Timestamps: 0:00 Is a Retired F1 Car the Ultimate Track Toy? 4:22 How did you form an interest in cars? 6:34 What’s a race weekend look like in Formula 3? 7:59 How do limited slip diffs work? 9:19 Tell us about Mercedes F1 14:00 What is TDF and how did it come to be? 18:20 How does TDF Works get a hold of used F1 cars? 22:22 Used F1 engines, are they hard to find and get running? 27:45 How do we get a trans axel for one of these cars? 31:50 What is seamless gear shifting and how does it work? 34:41 How do you go about running these cars on old electronics? 45:03 How do you source replacement body and aero parts? 49:50 Can you put something like a Judd V10 in one of these chassis? 52:37 What’s it look like for TDF Works to take a F1 car to the track for the day? 58:04 Can you give us an idea of the hydraulic system? 59:05 What is TDF One and how does it work? 1:02:55 How much of a debate was it to go to a turbo 4 cylinder? 1:06:29 How much HP are the genuine F1 cars making compared to TDF One? 1:07:59 What is the 4 cylinder engine in the TDF One cars? 1:11:03 Are you running a F2 trans axel in the rear? 1:12:52 What’s the electronics package and have you added ABS & Traction control? 1:15:46 How often do you need to overhaul the engine and gearbox and other parts? 1:20:50 How does crack testing on carbon fibre work? 1:22:15 How much does a TDF One car cost to run? 1:23:57 How many TDF One cars are out there? 1:24:44 What’s the build time on one of these cars? 1:28:26 Final 3 questions

343

1T 38min

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