Body:
Significant weight savings opportunities were obtained by replacing various body components with alternate products.  Fiberglass doors, hood, and rear deck lid offered significant weight savings.  Lexan windows were used to replace the heavier glass windows.

Lexan is more flexible than glass and when used to replace the front window the SCCA requires at least 3 interior supports.  While this is a safety feature to help prevent the window from penetrating the interior in a crash use of the braces it also helps the window keep its shape at high speeds.

 
Pictures:
 

Lexan window Lexan side windows Lexan rear window

 

Parts:
Fiberglass Hood
Description: Light weight fiberglass hood
Benefits: This fiberglass hood replacement weights only 12lbs.  The hood features all of the stock mounting points for bolt on application.
Fiberglass Doors
Description: Light weight fiberglass doors
Benefits: These doors weigh only 7lbs each.
Notes:

These doors took a significant amount of work to properly fit them to the car.  The door are equipped with hinge studs that are too close together so stock hinges will not fit without significant effort to expand the mounting holes.  None of the cutouts are in place for the door handles.  It took careful handwork to cut the openings and grinding to thin down the fiberglass so that the door handle mechanisms would mount.  There are no mounting holes for the door guards so we had drill our own holes and bolt them on.

Rear Deck Lid
Description: Light weight fiberglass rear deck lid
Benefits: This fiberglass rear deck replacement weighs only 5lbs.
Notes: The deck provided mounting points for the catch but no provisions are made for the license plate lip (useful in opening the trunk) and for the rear deck lock/release.  It was a very challenging process to cut out the proper openings through compound angled surfaces.  With patience and attention to detail we were able to mount the lock/release and mount the license plate lip.  We added the M3 logo and the finished result looks very much like the factory original.
Lexan Windows
Description: Lexan windows were used to replace stock windows
Benefits: Lexan is a lightweight replacement for the heavy stock glass windows.

Back...

©2005, Green Light Motorworks, Inc. All rights reserved. HyperLink