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5 Star Cases Cars for Arden Motorsports
International Formula 3000/GP2 Series Trust Team Arden asked 5 Star Cases to build two enormous flightcases to house their two GP2 cars that run in the GP2 Asia Championship.
5 Star has cased objects of all sorts in its history, but this was a first for race cars!. It was also 5 Star's biggest project to date in physical dimensions, with the overall case size ending up 3.9 metres long by 1.7 deep and 1.2 high.
Arden wanted to replace their timber packing crates with professional, re-usable flight cases. "The cases needed to be lightweight - less than 400kg - and very sturdy," explains Arden's team co-ordinator, Deborah Lyall. "They also had to be strong enough to accommodate equipment boxes stored on top, as well as security guarded and fitted with lift struts for both front and side loading."
The cars are transported to Shanghai, Dubai, Bahrain, Dubai and Kuala Lumpur by air, land and sea so 5 Star selected their hugely tough Super Tour spec. However even this required further strengthening and additional stability features to ensure the vehicles enjoyed the maximum protection. The deadline was also extremely tight!
A basic case design was created and submitted to Trust Team Arden, and the approved designs then imported into the Solid Edge 3D modelling software used by 5 Star, and produced as accurate renderings. At this stage, the project also suddenly multiplied into an order for six cases as two other GP2 teams - DPR of Surrey and Supernova of Norfolk - decided to get in on the case action for their own cars.
The basic case shells were constructed from 12mm plywood, bonded with high pressure laminate. Support for all the internal edges and joints was enhanced with 50mm aluminium angle extrusions, riveted right though the case. The internal dimensions were only just larger than the actual race car with its nose cone and tail assemblies removed, so accurate measurements were critical. External dimensions were also a key factor, as standard shipping containers are utilised in transit.
To aid fork-lift handling, the cases were supplied with specialist aluminium profiles bolted to their bases to give additional rigidity to the overall case. The case design features a removable front and top lid for easy access and loading of the vehicles. To prevent the lid sagging, three removable welded aluminium frames are spaced evenly along the entire 3.9m length. These support frames were fabricated exactly to the internal height of the case, so when fitted in place, they support the lid, enabling another complete cased race car to be stacked on top.
Eight roping recessed eyelets were fitted to the case ‘floors' so the cars can be securely strapped down for freighting, and the removed nose cone and rear tail assemblies are simply placed on top of the car in the case for travel.
Deborah Lyall comments on working with 5 Star: "They were great right from the start - enthusiastic about taking on the brief and ensuring that we were kept fully informed throughout the whole project. They prepared one box first and tested it out fully with one of the teams before going into full production with the other five. They are very professional with great customer service!"
15th October 2008
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