BUILDING THE SUPERMILEAGE CAR

It all starts with a drawing

It all starts with a drawing

top and bottom plugs were made from the drawings

top and bottom plugs were made from the drawings

The plugs then got smoothed out using bondo and extreme sanding

The plugs then got smoothed out using bondo and extreme sanding

20181130_Bottom Plug Sanded 4.jpg

The plugs then have to be primed

The plugs then have to be primed

And an adorable small car has to be made too… for… science?

And an adorable small car has to be made too… for… science?

20181229_Top Plug Priming 10.jpg

wax on...wax off

wax on...wax off

20190118_Top Plug Need Some Filling to Repair Damage.jpg

The plugs then got layered in gelcoat and fiberglass

The plugs then got layered in gelcoat and fiberglass

Then it gets removed from the plug

Then it gets removed from the plug

and a mould is born!

Top mould

WAX ON WAX OFF

wax on wax off wax on wax off

wax on wax off wax on wax off

wax on wax off wax on wax off

...shiny

Carbon fiber layup in the bottom mould

Carbon fiber layup in the bottom mould

This is where the body is born!

20190219_Carbon Fibre Layup in Bottom Mold 3.jpg

Then a layer of Soric was strategically placed on both the top and bottom moulds

Then a layer of Soric was strategically placed on both the top and bottom moulds

20190219_Soric Layup in Bottom Mold 4.jpg

20190309_Bottom Half Infusion 2.jpg

20190318_Bottom Piece De-Molded (SEXY).jpg

20190327_Top Piece Infusion 1.jpg

20190401_Top Piece De-Molded 1.jpg

20190404_Bonded Shell Trimming 1.jpg

20190404_Top and Bottom Piece Together 1.jpg

20190420_Checking Engine Platform Placement.jpg

20190420_Reinforcing Fabric on the Inside of the Shell.jpg

20190424_Driver Fit Check with Firewall.jpg

20190501_First Windscreen 1.jpg

20190506_Wheel Cutouts (keeping as much material as possible).jpg

20190514_Bay Cover Front (Stepped Layup to Reduce Machining Time).jpg

20190521_Genius Steering Design (rubs nipple).jpg

20190521_Side Window Cutout 1.jpg