sly's BvS DOJ Build
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Posted 10/29/2016 3:11:03 PM


Supreme Being

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Last Login: 4/6/2024 5:28:59 PM
Posts: 1,684, Visits: 5,334
This thread is getting quite lengthy, so I have decided to add this table of contents so you don't have to wade through sections that don't interest you. There is valuable information throughout of course, and the progression shows the learning curve that has transpired for sure.

sly




Thread Table of contents!

Page 1-20 Building a wooden mockup version.
.
Page 20-22 Completion of this phase with Halloween display
.
Page 22-26 Building a CNC Router from scratch to begin producing a fiberglass body
.
Page 28- ? First foam body production to make plug mold for fiberglass body. (Turned out to be too
large)

.
Page 54-63 Second foam body created
.
Page 63-71 Creating the Main Body Mold
.
Page 72-76 Laying the fiberglass in the mold to create the main body
.
Page 77 - ? Production of the side boxes
.
Page 78 - ? Putting the main body on the donor car

Post #150597
Posted 11/1/2016 5:52:33 PM
Has NO LIFE!!

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Last Login: 12/4/2023 11:08:55 PM
Posts: 3,232, Visits: 5,166
hey sly,
I like many others will be looking forward to your progress postings and photo images. Will you be mocking up the whole vehicle and then translating the wood pieces into steel. vertigo
Post #150613
Posted 11/1/2016 7:24:24 PM


Supreme Being

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Last Login: 4/6/2024 5:28:59 PM
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I'm thinking that might be a good idea. I can work out concerns before hand and when I go to steel it will move much quicker. What do you think?

I would love to have the body, as shown in my avatar, mocked up by spring.
Post #150615
Posted 11/2/2016 5:39:04 PM
Has NO LIFE!!

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Last Login: 12/4/2023 11:08:55 PM
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SOME INFORMATION ON BUILD STRATEGY: MOCK UP VS DIRECT BUILDING THE DOJ
“I'm thinking that might be a good idea. I can work out concerns
beforehand and when I go to steel it will move much quicker. What do
you think?”  sly

I believe building the whole vehicle in wood is a great idea because
fitting wood together is a lot easier than fitting metal. Once the
wood vehicle is completed you will know everything is fitting right
and you will have a set of fitted templates to translate into cut
steel parts. Rather than increasing build time, I actually think
building the vehicle in wood first, will actually save a lot of build
hours. vertigo
Post #150621
Posted 11/2/2016 6:13:48 PM


Supreme Being

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Last Login: 4/6/2024 5:28:59 PM
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Yep, that's right along with what I'm thinking.
Post #150622
Posted 11/4/2016 7:39:07 PM


Supreme Being

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Last Login: 4/6/2024 5:28:59 PM
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Added the air scoops.

It is quite interesting, looking at the original it always looked like the part in front of the air scoops was flat and the angle increases past the scoops. This is backed up when you view the chassis without the skin on. The tube frame is flat through the air scoops and then angles up to the dash. Well, when I added the air scoops to my mock up those exact angles happened automatically! It was like magic.

Also, I spent a lot of time measuring distances and angles to get the curve of the skin right when I framed it up, but when I added the scoops all of that happened magically again!

Unfortunately, you probably can't see any of that in this pic.

Batmobile

I'm not sure exactly how wide to make the scoop divider. This is set up for 2" but I think it might not look wide enough. What do you think? That's something I will need to play around with.

Batmobile

I also added 2x2s around the edges to add the look of thickness needed and to stiffen the edges.

Batmobile

Next I will work on that scoop divider, the curved bar that is the point that the dashboard connects, the openings in the skin for the defensive weapons and helicopter tow points.... as well as the cut outs in the front edge, and altering the frame to fit this skin. Oh, and adding the wheel flares that are a distinctive feature in my opinion.

A couple of things I noticed at this point. It looks like the front wheel will need to be no bigger than 26" in diameter and probably more like 24". I thought they would be bigger. (That's the actual wheel, not the wheel cover) Also, This has made it very clear where the upper chassis tubing should go. That was my main goal.
Post #150630
Posted 11/4/2016 7:40:07 PM


Supreme Being

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Last Login: 4/6/2024 5:28:59 PM
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Not sure why pictures are not showing. I will check back later and see if it works. But for now you can right click the picture, copy the url and open it in a new window.
Post #150631
Posted 11/5/2016 3:17:44 PM


Supreme Being

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Last Login: 4/6/2024 5:28:59 PM
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Added the turret base plate today.

Batmobile

Made this out of half inch plywood. Would probably use quarter inch steel plate for this and maybe 1/8th inch plate for the skin. Not really sure yet.

And what it looks like on the mockup.

Batmobile
Post #150633
Posted 11/8/2016 2:07:58 PM


Supreme Being

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Last Login: 4/6/2024 5:28:59 PM
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Got a little more done to the mockup.

1. removed the 2x2 framing and replaced it with 1x2 framing because I thought the 2x2 was a little too thick.

Batmobile

2. cut the notches in the front panel.

Batmobile

3. Made the front clips. Looking at the models I thought these were used to hold the gun turret on, but looking at the real car it seems they are clamps to hold the air intake ducts on. A bit of a silly way to do that but I suppose they wanted something that looked heavy and industrial. For those that don't know what I'm talking about, here it is on the real car.

Batmobile

Here is a mockup clamp I made:

Batmobile
Batmobile

This is one thing that would have been easier to make out of steel. Here it is attached to the car:

Batmobile
Batmobile
Post #150639
Posted 11/12/2016 3:41:45 PM


Supreme Being

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Last Login: 4/6/2024 5:28:59 PM
Posts: 1,684, Visits: 5,334
Added the front wheel flares today.

Batmobile
Batmobile

Starting to look more like the car now. I am not including measurements because I wouldn't build it this way in steel. I would make it more like an airplane wing, outer and inner wall tapered to the edges. If anybody REALLY needs the measurements PM me. I will tell you that the rise from the top of the body id 30 degrees and the angle of the bend is 20 degrees.

Batmobile

The width at the center point for the front wheels is six feet and three quarters of an inch. Not much room for the wheel outside the flares unless I can tuck them under somehow, say with air lift suspension. The space at the back is wider at about seven feet, but the wheels will mostly be forward of that area. That's more important for how far the side boxes will be able to stick out.

Next I plan to put in the divider between the air scoops and cut the holes for the front lift points and the defensive weapons array. Then I'll be ready to start the mockup of the front chassis and cabin.
Post #150651
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