Springfield Flyer.

[tauruck]

Nothings perfect but the palm sander with a 150 grit disc will flatten out  any high spots.

My only concern is the density of the foam. What I have is a "15"  and at only 10mm thick its fragile.
You don't look a gift horse in the mouth so i'm not going to hassle the sponsor to send a truck 60 miles
to bring a higher density product.

I'll work carefully and slowly.
The adhesive is excellent. A little thin for my liking so I added a thixotropic agent in the form of cotton flocks
and its just like putting peanut butter on bread.

The structure is pretty rigid for what it is so the next step should go well.
The pics aren't in chronological order but I think you'll get the idea.

Anyone thinking of using this "method" beware. Don't try using Polyester resin.

[wheelrdealer]

Great work Mike. I am fascinated to see how it turns out. You are the carbon fiber man!

BR

[Buickguy3]

   Mike, You've got my attention. Wish we lived about 5000 miles closer. I want to si in the corner of your shop like a fly on the wall.
    Doug 

[Finallygotit]

Got room for another fly?  Nice work Mike!!

[tauruck]

Flies like you guys are always welcome.

I had a birthday yesterday. Boring!!.

Did nothing and stayed out of the shop.

Today I did a little.

The nose plug is about 70% and should be done this weekend.

[tauruck]

There are no drawings or fancy stuff going on but I'm trying to avoid building another slab sided liner as was suggested I don't do.

Difficult to put swoopy lines on a rocket shape but we'll give it a go I guess.

Some pics of where things stand.

[tauruck]

Some side on views of the canopy/engine cover plug.

This car should be called the "Eyeball Special".

Only mishap today was that the darn rooster decided to try eat the nose plug.
He set me back some.

If I was 20 years younger I would definitely have killed him. Not fitness wise, I'll still catch him no problem but wisdom etc.
Rocking the boat by murdering the pet wouldn't be too clever.

[tauruck]

I forgot.

The neighbor is doing the wheel tubs for me.

[Buickguy3]

   Mike, I'm sure you've done it, but give yourself at least two inches all around the circumference for tire growth. That will leave some extra to spare. You don't need any kind of contact at speed. I'm sure I'm not telling you anything new.
   Doug 

[LeeTurner]

Hey Mikey - belated happy birthday brother. 

[Frankie7799]

Pretty bitchin looking Mike!

[wheelrdealer]

Mike:

Once again... amazing.

Do you file or trim that foam to get the round shapes? You have me thinking, I want to build a body just for the challenge of making a unique shape. I cannot wait to see how this goes...learning a lot from my LSR brother from another mother on the other side of the globe. Thank you for sharing.

BR 

[tauruck]

Hey Lee, thanks man.
Zee made the usual breakfast and invited "friends" but not one showed up.

Thanks Frankie and Bill.

Bill, I use a fairly high density Polystyrene for the base so it retains its rigidity.
Same for the ribs. 15  to 20mm thick.

I use a box cutter to cut the shapes after I've marked them.
Wire cutters don't work for me.

The skin or surface is 10mm low density sheet that is bonded over the ribs and the high spots are sanded flat with a palm sander (150 grit disc).

For the sharp radii I'll bond short sections and keep them down with masking tape until cured, then do some more. This foam is pliable to a degree but brittle so if you ask it to do too much it breaks.

Simply put, it's like skinning an air frame but instead of rivets and Alclad we use foam and glue.


Next task is to blow mould the canopy windshield. I definitely don't want a 2D shape there.

[Elmo Rodge]

Mike, it is my understanding that the optics are better if you drape form the canopy rather than blow it. I don't know why. You'd have to ask a grown up.  Wayno

[tauruck]

I'll do that Wayno.

Getting it right first time is a fantasy I guess.

I was going to make a male mold until I met Gary Lavarack via email.

He blow molded a very nice piece he said is water clear.
Check his video on Youtube.


http://www.youtube.com/watch?v=h9ODMVdoWXM