Vehicle Graphics Project of the Day: Winning the ALMS Race

The compound curves and complex contours that accompany modern vehicle designs can prove challenging to vehicle-graphics providers. However, these challenges pale in comparison to the obstacles that high-performance racecars impose. For vehicles that negotiate the American LeMans Series (ALMS), which models its competitions upon the 24 Hours of LeMans endurance race, the demands for precision preparation and application rise exponentially.

ESBG Design LLC (Miami Beach, FL) fabricated graphics for Patrón Highcroft Racing’s Acura ARX-02a racecar, which competes on the ALMS circuit. ESBG’s Jeff Borkowski outlined the project’s many challenges.

“There isn’t a single body, per se,” he explained. “The body comprises many individual pieces that we fit together like a puzzle. We do most of our work on individual pieces or on mocked-up sections of the car. This, coupled with the bodywork’s fragile nature, the expensive parts and the precision required to wrap these difficult body lines makes these jobs very time-consuming.”

ESBG is wrapping carbon body components – which Borkowski said can range from “tattered and patched to fresh out of the mold” – and must keep a stash of spare component wraps on hand to replace panels damaged while racing. Therefore, although it doesn’t assemble wraps in the manner of conventional shops, he estimates the shop wraps approximately one full car per race weekend (the ALMS series runs on 11 weekends from March to October).

“The team travels with two or three spare sets of bodywork, not all of which line up at the same time,” Borkowski said. “Each piece must be matched to a master set to ensure consistent decal alignment. Individual panels vary in terms of hardness, rigidity and structure, which can impact vinyl adhesion. For some thin pieces, such as over the rear engine cover, we had to apply a fine coat of body filler and a clear sealant to make the vinyl stick.”

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Each full car wrap measures 505 sq. ft., and each transporter’s graphics – ESBG produced two of these – spans 1,444 sq. ft. The complex panels comprise a mixture of Oracal USA 970RA (which contains a built-in, clearcoat layer) and 3951RA Rapid Air® air-release film with Oraguard 290 overlaminate, as well as 3M Graphics Market Center’s Controltac with Comply v2 air-egress film and 680 reflective media. The shop outputs the prints on its Seiko ColorPainter 64S, and cuts them to form on a Summa S Class T cutter and Desay plotter.

“Turnaround times often create a huge challenge,” Borkowski said. “It’s not unusual for us to have to complete a week’s worth of work in two days. And, we perform our work onsite at the team’s headquarters, which requires a mobile set-up. There’s no magic bullet; the Patrón car simply requires long hours and a skilled, dedicated crew.”

All photos are ©Richard Dole Photography

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