FRP is an acronym for Fiber Reinforced Polymer. Some will say that it stands for Fiber Reinforced Plastic, but this is incorrect – Not all plastics are polymers. In the case of Mugen’s manufacturing process, they use a proprietary FRP composite developed in-house after much testing in the lab, wind tunnel and street.

Some of Mugen’s aero pieces are constructed from FRP exclusively; bumper covers, side sills, spoilers. But Mugen manufactures two items from both Carbon Fiber and FRP – Hoods for Fit, and S2000, and S2000 Hardtops. The reasoning is pretty straightforward, Carbon Fiber construction is the strongest, lightest material available for these parts, but it comes at a cost. FRP, on the other hand, offers a lower cost option. While not as strong or light as Carbon Fiber, FRP is still extremely strong and still lighter that most other materials. Most importantly, it can be used in the same molds as the Carbon Fiber pieces, therefore offering the same precise fit that Mugen’s Carbon Fiber parts are known for.

Here are a few common questions regarding Mugen’s FRP parts:

Q: What is the weight difference between the Carbon Fiber and FRP parts?
A: The weight difference is about 25%. For instance, the Carbon Fiber Hood for the S2000 weights 34 lbs – the FRP unit weighs X44 lbs.

Q: How well does the FRP top fit?
A: The fit is perfect, just like Mugen’s Carbon Fiber Top. The same molds are used to produce both.

Q: Does the top come with all of the mounting hardware?
A: All the necessary hardware is included, as is the Polycarbonate rear window.

Q: What is required to get FRP parts ready to paint?
A: All of Mugen’s FRP parts come primed and ready for paint. Your body shop will only need to give them a light scuffing and thorough cleaning.

Q: Should I test-fit my FRP parts first, or can I go ahead and paint them knowing that they will fit?
A: It’ll fit, period. Paint it, install it and enjoy.

Below are some technical data regarding FRP (source: American Composites manufacturers Association):

Not all plastics are composites.  In fact, the majority of plastics today are pure plastic, like toys and soda bottles.  When additional strength is needed, many types of plastics can be reinforced (usually with reinforcing fibers).  This combination of plastic and reinforcement can produce some of the strongest materials for their weight that technology has ever developed...and the most versatile.

Therefore, the definition of a fiber-reinforced polymer (FRP) composite is a combination of :
-a polymer (plastic) matrix (either a thermoplastic or thermoset resin, such as polyester, isopolyester, vinyl ester, epoxy, phenolic)
-a reinforcing agent such as glass, carbon, aramid or other reinforcing material such that there is a sufficient aspect ratio (length to thickness) to provide a discernable reinforcing function in one or more directions. 

FRP composite may also contain:

- fillers

- additives

- core materials

... that modify and enhance the final product.  The constituent elements in a composite retain their identities (they do not dissolve or merge completely into each other) while acting in concert to provide a host of benefits ideal for structural applications including:

** High Strength and Stiffness Retention - composites can be designed to provide a wide range of mechanical properties including tensile, flexural, impact and compressive strengths.  And, unlike traditional materials, composites can have their strengths oriented to meet specific design requirements of an application.

** Light Weight/Parts Consolidation - FRP composites deliver more strength per unit of weight than most metals.  In fact, FRP composites are generally 1/5th the weight of steel.  The composite can also be shaped into one complex part, often times replacing assemblies of several parts and fasteners.  The combination of these two benefits makes FRP composites a powerful material system- structures can be partially or completely pre-fabricated at the manufacturer's facility, delivered on-site and installed in hours.

** Creep (Permanent Deflection Under Long Term Loading) - The addition of the reinforcement to the polymer matrix increases the creep resistance of the properly designed FRP part.  Creep will not be a significant issue if the loads on the structure are kept below appropriate working stress levels.

** Resistance to Environmental Factors - Composites display excellent resistance to the corrosive effects of:

** Freeze-thaw: because composites are not attacked by galvanic corrosion and have low water absorption, they resist the destructive expansion of freezing water.

** Weathering and Ultra-Violet Light: FRP composite structures designed for weather exposure are normally fabricated with a surface layer containing a pigmented gel coat or have an ultraviolet (UV) inhibitor included as an additive to the composite matrix.  Both methods provide protection to the underlying material by screening out UV rays and minimizing water absorption along the fiber/resin interface.

** Chemicals and Temperature: Composites do not rust or corrode and can be formulated to provide long-term resistance to nearly every chemical and temperature environment.  Of particular benefit, is composites ability to successfully withstand the normally destructive effects of de-icing salts and/or saltwater spray of the ocean.

** Fire Performance of Composites - FRP composites can burn under certain conditions.  Composites can be designed to meet the most stringent fire regulations by the use of special resins and additives.  Properly designed and formulated composites can offer fire performance approaching that of most metals.

It was just after 8am. The weather was looking good. Big Mike and other staffers were hauling the goodie bags out to the welcome tent. Although we still had about an hour to go before the start of Dyno Day 2011, the first cars were already rolling up. The Urban Disturbance car club had arrived early, and they had big plans for the day. They settled into choice parking spots and set up a portable tent of their own (complete with their website URL). Throughout the day the members would impress the hundreds of attendees with their clean builds and jaw-dropping dyno runs. By day's end, Urban Disturbance proudly picked up the lion's share of awards. Their members took home awards from 3 of the 5 categories: Spirit of JDM, People's Choice, and King of the Dyno. From start to finish, this club stole the show.

Who is Urban Disturbance? We interviewed their members about its influential club, their rides, and their connection to King Motorsports.

How did Urban Disturbance start?

Urban Disturbance (UD) Car Club started in 1998 with mini trucks and low rider styled vehicles.

The club was formed by Chris McCauley (now referred to as ‘The God Father’) along with a group of friends: Jon Jezo, Chuck Glissendorf, Kris Walker, and Matt York. It all started right from the roots of many of today’s enthusiasts: custom built vehicles, built in a driveway garage with no luxuries, special tools, or sugar daddies.

How many members do you have today? What kind of cars do they drive?

Currently we have 25 official members. Most of them have sport compact cars but there are vehicles of all types -- trucks and bikes too. Although we dominate with Hondas, we are receiving applications from all makes and models on a daily basis.

Which members and cars are the most influential in the club?

As a club we are all influential to each other, we push everyone to do bigger and better. Spaz is known as our head mechanic, most people bring their cars to his garage for modifications and repairs. Spaz has an '05 RSX K24 swapped, supercharged and tucked. Chuck (aka “Chucks Tucks”) is influential for many who want that clean tucked engine bay -- they go to him. Ole (2x "Spirit of JDM" & "People’s Choice" award winners) has a shaved & tucked, RHD true JDM ITR DC2 that everyone drools over. And our club President, Jezo, has built a 500+whp 4cyl beast RSX that gets plenty of attention (2x "King of the Dyno" winner).

Were there any runner-ups names for the club?

"Driveway Customs" & "Disturbed Customs."

Are there requirements to join the club, and how does someone join?

Anyone can apply to join by simply filling out our online application and sending three photos of their ride. Our requirements consist of a vehicle that is complete, street ready or a quality build with progress demonstrated.  New members have a probation period in which they must attend 3 events in a season, such as car shows, meets, track days, etc. (at least one event being with your ride). 

What kind of events and outings does the club attend and how often?

Our club enjoys going to local, regional, and national auto events to show or race our rides and to just look at the latest trends and styles. We also love track days at the local autoX spot, drifting spot, or Union Grove Great Lakes Dragaway (Import Wars) and Byron Race Tracks.  This year our club attended a huge event called Import Alliance with over 10,000 other enthusiasts in Nashville, Tennessee. Almost every weekend day you can find our members at an event of some type.

Is there a city that the club calls home base?

Janesville, WI is the home base of UD.  We now have an Illinois chapter and are accepting applications for new members and chapters everywhere!

What makes Urban Disturbance different from other car clubs?

We try to keep a good strong mix of everything. From high horsepower builds, to full engine shave and tucking, to full custom air ride, track, autocross, drifting etc. This way our club can get out, adapt and grow everywhere we can.  We take great pride in our rides and want to support the scene in a classy manner.

How did you come to know and work with King Motorsports?

Anyone truly passionate about Hondas knows the famous King Motorsports. Since we're mostly in the Honda scene, we are all fans of King Motorsports. Several members have bought parts, gotten tuned, and visited the facility. Also King is one of the few tuner shops that you can order quality parts from... including official Mugen parts. 

You guys really cleaned up the awards at King’s Dyno Day 2011!  Any advice for people who want to create award-winning builds?

Come to us! LOL. Seriously though, just take your time and do things right. The problem with builds we see online is there are too many people buying cheap "eBay knock-off" parts. Everyone buys a Honda and says "yeah I’m gonna boost it…blah blah blah," but talk is cheap. Money is the issue. So take your time, build it right. Better quality parts = better results every time.

Over the years, what type of tuning or work has King done on member rides?

King was the influence for Spaz doing an Electronic Power steering swap in his DC5. According to the forums the 2005+ RSX-S cannot use EPS without a speedo healer converter but with the help of King Motorsports they were able to figure it out and his EPS works great.   Another member, Ahmad, has gone through King Motorsports for a lot if not all his parts.

What makes King different from other shops like it?

Quality. King Motorsports is the high end of dealers, mechanics, and engineers. There are plenty of tuners and shops, but none of them with the reliability and reputation as a place like yours. To most people, when you see a car built by King you knows it’s quality and built right!

Do you have any stories about King Motorsports you'd like to share?

Anyone who hasn’t been to King Motorsports for their annual Dyno Day needs to check it out!

Parting thoughts?

No matter what happens in life you can’t let it get you down.  If cars are one of your passions don’t let it get away from you.  Cars come and go but the passion remains, find it and keep the scene alive.

To all the other Honda, import, and auto enthusiasts out there: Please remember to support the scene, give back to the next gen, and skip that last helping of rice.

>> For more information about Urban Disturbance (including membership, show calendar, forum and club store) look them up at urbandisturbance.net.