Stan Wallace and the Carbon Fibre Revolution in Motorsport

The prominence of carbon fibre in the realm of South African motorsport is undeniable. A shining example of this is the multiple victorious Toyota Hilux in the Dakar Rally, an engineering marvel built by Hallspeed, who manufacture the FIA specification racing bakkies on behalf of Toyota. The racing Hilux is a testament to the prowess of carbon fibre, with composite pieces making up the shell of the vehicle and replacing most of the plastic, steel, or aluminium components found in a typical Hilux. The task of crafting these parts lies with a dedicated team working from a smallholding in Henley on Klip in the south of Johannesburg, led by none other than Stan Wallace and his team at Wallace Race Composites.
The Man Behind the Composites – Stan Wallace

Stan Wallace is a pioneer in the field of composites, with a love for the material dating back to the 1970s. While still in school, Wallace started experimenting with composites for canoes and paddles, which led to a bursary to study composite engineering. Even during a ten-year stint in the Police service, Wallace continued to hone his craft, seeking competitive advantages on the water for himself and his wife, who were both competitive paddlers. His long standing relationship with composites supplier AMT Composites has aided him in pushing the boundaries of what can be achieved with composites.
The Journey to Motorsport

Wallace’s journey into the world of motorsport began in 2014 when he was contacted by Glyn Hall to build a lighter rear spoiler for the Toyota Yaris rally car. Wallace’s part was 130grams lighter than the imported European part, leading to more commission work for Hallspeed. When the Toyota Gazoo Racing Hilux was being remodelled, Wallace and his small team worked tirelessly to complete the car. Their precision was remarkable, with much of the sculpting done freehand. The final car was within 3mm of the team’s computer renderings.
The Magic of Carbon Fibre

With a team of no more than six members, Wallace Race Composites matches the quality of world-class composites produced by teams like Audi, Peugeot or Mini, who employ 40-60 staff members. The team now builds more than a 100 different parts for the Toyota Gazoo Racing Hilux, with each part tailored to the specific requirements of different events. The benefits of carbon fibre are numerous, with significant weight reduction being a prime advantage. For instance, the weight of the door has been reduced from 22 to 4.2kg, and the bonnet is down from 18 to 3.2kg. Despite specific weight requirements for the cars, the lightness of carbon fibre allows engineers greater flexibility in weight placement, benefitting the handling of the vehicle.
The Tears of Success

The commitment and dedication Wallace has put into his work is terrifyingly immense, with 6 months of 80 – 90 hours per week spent to make every single composite part for a Dakar winning Toyota Hilux. On one occasion, the last part was delivered in the early hours of the morning, was fitted and the car was flown to Dakar hours after part fitment. The intensity of the work is exemplified by Wallace’s recollection of a tight deadline for a set of doors in 2017, which saw him having a finger amputated under local anaesthetic and returning to work to ensure the parts could ship out on time. In 2023, 23 cars used parts made by Stan Wallace and his team at the Dakar.
The Future of Wallace Race Composites

Following the latest Dakar victory, Wallace Race Composites is expanding into the automotive aftermarket. They are at the final stages of developing composite parts for one of South Africa’s most popular bakkies, set to be significantly lighter than conventional steel bulbar while maintaining equal strength. The journey of Stan Wallace and the use of carbon fibre in motorsport is a testament to talent, innovation, dedication and simple hard work. As Wallace continues to push the boundaries of what can be achieved with composites, the world of motorsport will undoubtedly continue to benefit from his pioneering work.

Stan Wallace and the Carbon Fibre Revolution in Motorsport

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