the work continues

As I said in the last article, our goal for the 2 last week was to continue the main body upper part (the nose upper part), the back suspension and the chassis jig.
We did so.

The nose:

The approach was exactly the same we used for the main body bottom part. In fact, we started to make a good shape from the raw polystyrene foam. We put a fiberglass skin to make it solid. Then to make the sanding easier, a Epoxy skin is added (with a lot of Q-cells).
We sanded the body, added another layer of epoxy, sanded again the body and finalized the nose by filling the holes with some polyester. We also focused on the windscreen junction with the main body.

Windscreen junction

The last step was to paint the nose in grey to find the last tricky little holes. After a last fill in, we are now able to go through the final painting!

Grey painting

At the same time, we also worked on the windscreen. Using what we did on the main body, we were able to have a good idea of what the car will really looks like (using some additional wood slices and wooden rods).

Thanks to that, we made a first windscreen. Our goal was then to make the mold for the glass manufacturer. But we knew lots of modifications were up to be made. That is why we keep on fitting that windscreen with the main body.

Windscreen mold

Our last plan is to focus on the roof (by modeling it into raw foam) and to adapt the windscreen top. We will then be able to get a really nice top shape.

The rear suspension:

As I mentioned in my last article, we also wanted to finish the rear suspension.
After having design them during last month, we finally made it. That work called for some blue prints to cut the 2 aluminum pieces. Then we welded these pieces with some other ones to make the structure stronger and to be able to correctly settle the wheel on the suspension. Finally, we assemble the rear suspension. Nice, isn’t it?

Rear suspension

The jig:

During the last few days a flood came down on us. Because of that, we were forced to change our plan with the jig and make it really stronger (the timber jig became soaked with water and broke). That is why we started to build that in steel.

The new jig

As a result, we hope that the main body mold will be finish in the next few weeks. We will then be able to make the mode and to get the first main body!
At the same time, we keep on building the jig (in steel) and we are going to move on to the front suspension.