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finished building the sill inner areas. Still need to sand and polish some of the visible areas to get a flat and polished finish before i drop the spider on. The spider is ready to be dropped onto the tub. I made the window aperture panel and have bonded it in. I will do the rear bulkhead...

first test fit, starting to look a bit more like a car now ! got some more work to do on both upper and lower before i join them for good, maybe in a few weeks. Then .. window aperture, rear bulkhead, seats.

Made the sill inner panels, checking fit and alignment, hoping to get them bonded in next week

Thanks Vinny, I have had some success and some failures with the 3d printed CNC. Have been able to machine aluminium reasonably well, but I found if I try to cut for too long in one go two things happen .. The 3d printed parts start to soften from the heat and i lose stiffness, and second the...

June update; Decided to coat the tub in a layer of UV resistant epoxy to protect it and to also rework some places with dry areas, so have been busy last few weeks sanding and polishing. Now need to find the suspension mount inserts and remove the plastercine, then attach the Sill inner panels...

23 kilos of epoxy resin later .. Now need to patiently wait a week or more to fully cure before demoulding it, don't want to risk distorting the geometry. After days of fruitless vacuum leak hunting I double bagged it, the second bag going all around the whole mould too in case that wasn't...

Tub update .. got all the plies laid up, peel ply and mesh layers on and bagged up .. now comes the great air leak hunt. Already a few hours in and still LOTS of leaks to sort.

slowly starting to assemble the tool for the tub. re-checking and re-polishing each section in turn before bolting and sealing in place. Another week or so for this, then a leisurely 4 weeks or so of laying the plies into it, another week for the consumables layers and another for chasing air...

Yes I use fusion for most cad work, its a really powerful tool considering its free for hobby use. For the composites process work I strongly suggest to watch the videos on Youtube by 'easy composites', they are really well put together and show everything step by step, I buy a lot of my...

Ok, new year and time for a new update. While I wait for the warmer weather to mould the main tub I have been working on some of the smaller panels that I can move indoors to cure. The part in the picture is the RH sill inner (it will join to the main tub to close the sill section). I had some...

Hi Michel, glad you like it ! thanks for the heads up, I got a recess in there for the screen, in the image below the screen bonds to the hashed line area, and the area circled there is a 9mm recess so the screen is flush with the roof. I decided to design it so that there is no visible A-pillar...

October update, mostly finished with the tooling now for the main tub. I'll let the moulds sit for a while to cure some more before taking them off the pattern. I think I will have a bit of a wait now before I can use them, the weather is too cold now to cure epoxy parts in the garage. I will...

oops, some problem with the photo, try again ..

Finished sanding and polishing the pattern for the main tub, just waiting on some polypropylene sheet to arrive so I can make the flanges for the mould splits and then i can get fibreglassing the first section. Once the moulds are made I will have missed the warm weather window for infusing the...

Hi guys, in between prepping the moulds for the carbon tub i'm trying to sort the tunnel package and hope some of you more experienced guys can weigh in with some thoughts. I plan to route the main cooling pipes and the rad air bleed line down the tunnel. first question, is this likely to be an...

Main tub pattern now primed. Fair bit of sanding to do now .. see you in a few weeks

ICE or EV, EV or ICE .. why not both clearly we need to try new energy sources, not just for the environment, but also for the fact that gasoline is a finite resource. Some day it will dry up and i'd like to know that my kids and their kids can still enjoy cars like we have. Like it or not we...

got up off the ground and able to spin now more filling and sanding and sanding and sanding and polishing !

started making the pattern for the tub mould, mostly plywood with a few local 3d printed sections for details. The main tub only extends as far in as the top of the sills (rockers), I'll make separate patterns to make moulds for the sill inners. i'll be making it on a rotating rotisserie...

found another little thing for the kids to get involved with .. dismantling of the old buck .. they enjoyed this part of the project