Aerodynamics of a Touring Car are always restricted by regulations which have to be carefully studied by our designers to consider the many constraints put upon them. Three equally important aspects of the aerodynamic tuning of a modern Touring Car have to be equally balanced : firstly to minimise drag, secondly to provide downforce and thirdly to balance this downforce between the front and rear. This creates a trade off between what we call downforce and drag.

The model is produced firstly by making a pattern. The shape of this pattern is generated at 888 from original Vauxhall CAD data then sent directly to our CNC milling machines. CAM software then translates the CAD data into cutter paths and and the pattern is machined from a piece of medium density tooling block 1600 mm X 600 mm X 600 mm. The finished pattern is an exact replica of the shape of the car at 30% scale and is sent for finishing and polishing to the composites shop.

A carbon fibre mould is then layed up in sections on top of this so that we have a perfect female 'image' of the car. This sectional mould can then be bolted back together accurately and finally a male carbon fibre shell layed up into this then cured at high temperature and pressure. The finished model is accurate, lightweight and very stable. Onto this bare shell we start to add miniature suspension parts and wheels created in house in the fabrication shop so that the car is a perfect working model, just missing an engine.

Using the designers experience a selection of front splitters and other devices can also be modelled to the same scale and fitted to the model in a way very similar to the full size car. This complete package can now be wind tunnel tested to see which devices work best. Small modifications can be made at the wind tunnel itself using a plasticine-like filler to smooth curves, define and create edges and to try other ideas.