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 Posted 8/31/2018 12:21:44 PM |
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Supreme Being
 
Last Login: 4/6/2024 5:28:59 PM
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Visits: 5,334
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Thanks for the kind words Vert and Bbop. I was starting to think this place was a bit deserted.
Yeah, it's big.
Even with a 12% reduction from the original size it will wind up being over 20 feet long. Probably around 22 feet. This part of the bodyshown in the pictures is 16 feet, and there's another 23 inches on the back yet to be milled. Then the rear wheels and areo wings extend beyond that. The width of the body pictured is 8' 6" so wheels and suspension will have to be no wider than that as well. I wouldn't want to go any smaller as the cockpit interior is barely big enough for a two seater as designed. You could go smaller if you went with a single seat cockpit.
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| Posted 9/3/2018 6:25:32 PM |
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Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
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Visits: 5,166
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Your build seems to be progressing well.
What are your building goals for September and the rest of 2018? vertigo
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| Posted 9/3/2018 8:46:12 PM |
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Supreme Being
Last Login: 4/6/2024 5:28:59 PM
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This week I won't be able to do anything on it. By the end of Next week I hope to have the rest of the body milled. After that I will work on finish sanding and prep. Last week in September may see the laying of fiberglass and making the mold. That might be a question though as it's not only fiberglassing that needs to be done, but also the reinforcing support structure that needs to be made.
During the winter I will work on milling the side boxes and wheel covers.
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| Posted 9/13/2018 9:42:17 AM |
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Supreme Being
Last Login: 4/6/2024 5:28:59 PM
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Visits: 5,334
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Finished the outer rear sections. As you probably already know, the CNC 3 axis router can not under cut. So for this section I needed to slice the file into a top half and bottom half to get the detail I want. Even with that there are some places that were under cuts. Here are the two sections before any modifications. Part is sitting on it's front edge)
Notice some edges don't match because of the under cut. Here are the pieces joined together and the undercuts and sanded in.
And the piece laid down as it will connect to the rest of the car.
Only have the two inner sections still to mill. Might start prepping some of the parts for mold making this weekend and finish up those two sections next week.
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| Posted 9/13/2018 8:09:46 PM |
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Has NO LIFE!!
Last Login: 12/4/2023 11:08:55 PM
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Outstanding progress sly.
How do you think it will take to complete the milling?
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| Posted 9/14/2018 9:19:27 AM |
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Supreme Being
Last Login: 4/6/2024 5:28:59 PM
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Visits: 5,334
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The body is almost done. I am finishing one of the two sections left today. the whole body should be done early next week, depending on if my wife has any other projects she wants me to do. 
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| Posted 9/15/2018 1:29:45 PM |
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Supreme Being
Last Login: 4/6/2024 5:28:59 PM
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Experimenting with mold prep today. Took two sections from the front driver's side:
1. fastened them together. Marked the lines with a black marker so I can go back and rout those out after the surface is sealed and hardened.
2. sanded off milling tabs. Decided not to do more sanding until later because I thought the small ridges left from milling would help hold coatings in place.
3. Used spackling compound to fill holes as this is what was recommended on several fiber glassing over foam sites. Turned out to be a mistake.
4. Used white glue to seal the foam. This worked OK with the spackling but I was not happy with the overall result.
5. Used Epoxy resin to seal the part. This worked out great but the spackling compound and the white glue softened up when this was applied. Spackling is unnecessary anyway as the resin fills small gaps nicely and the next stage will take care of larger gaps. Problem with the epoxy resin is that it takes quite a while to cure. I need to get some with a quicker cure time.
Next step will be to skim coat this with a thin layer of body filler putty and sand to a finished surface. Then it will be ready to turn into a mold.
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| Posted 9/15/2018 2:16:27 PM |
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Forum Member
Last Login: 12/6/2023 2:20:22 PM
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| Can’t wait to see it all in one piece. You must feel good every time a panel takes shape.
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| Posted 9/15/2018 6:54:38 PM |
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Supreme Being
Last Login: 4/6/2024 5:28:59 PM
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I do!  I have one more section to do, but tomorrow I'll post pictures of the section I finished today. It came out awesome.
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| Posted 9/16/2018 2:33:28 PM |
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Supreme Being
Last Login: 4/6/2024 5:28:59 PM
Posts: 1,684,
Visits: 5,334
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Finished milling the drivers side rear of the car. You can't really tell from the pix but this section is large.
Here is a closer look at little wing in the back. Notice there is an indent in the body that is not milled all the way down. That's because the milling had to be done in two directions so the machine couldn't see that part. I will need to cut it out by hand there.
Here is a closer look at the top rear. The box that's carved in is for air vents that cool the motor. That will get cut out after the body is produced. Again, the top of the cabin is suppose to be angled back but the CNC machine can't under cut so it just made it straight down. I can either cut it out by hand or just leave it like that. Right now I'm leaning toward leaving it rather than risking messing it up with a free hand cut. What do you think?
Here's a look at the underside milling.
And a couple more pix just to be complete.
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