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its been a while since my last update but things are still ticking over slowly. Finished making the all of the moulds for the outer body, and have made the main upper structure part. I tested a better way of doing the aluminium inserts (the cross-beam at the rear has 4 fixings for seat belt...

progress update, got the RH door off now too. All thats left of the original buck will now be the main upper structure. Bit of a fiddly part this one as I need to get the flanges offset just right as they will be mounting the door seals, so offset distances need to be right.

So .. finished the car .. sort of. Painted up the 3D printed scale model that I had already made as a task I could finally actually do with the kids. I asked them what colour it should be, one said blue one pink .. so its half n half.

Thank Dave, I'd not seen that particular one but I think I've seen another video of the same guy forming his own screens from polycarbonate. Lots of good ideas ..

end of year update .. finished the moulds for the LH door now. Next i'll be working on the RH door and finally the upper structure - that should take me up to the spring. Then I can give the garage a proper clean out and get ready for the next stage.

Mesa - Here's some snaps showing the process. First, make sure you have everything prepped. Once you start you'll have sticky hands and the clock will be ticking so I get all the plies cut out and counted, find a good movie to put on and open a beer all before the epoxy is mixed. step 2, mix the...

Mesa - Here's some snaps showing the process. First, make sure you have everything prepped. Once you start you'll have sticky hands and the clock will be ticking so I get all the plies cut out and counted, find a good movie to put on and open a beer all before the epoxy is mixed. step 2, mix the...

Hi Tom, yes I had been wondering the same. I'll likely either add a vent over the fender, or adjust the trim line for the hood to pull it outboard nearer the tyre, let the air bleed round the side. I'm also concerned about the rear, the engine bay is very open, lots of drag, and not very...

Hi Jasper, yep I used mostly UD, with a bit at 45 and 90. I found that with the wet layup over a tight shape its hard to keep it from wrinkling up under vacuum so I laminated it in 4-5 stages sanding back smooth inbetween. I ended up putting down extra 45deg layers as last layers each time as...

I have been slowly collecting certain parts as i finish areas of the design, buying things that i'm going to need to design other things around .. mostly boring things like seals and bushes .. but these were more exciting !

CF wishbone factory running nicely. Put a TV in the garage for some entertainment while laminating. Finished full front LH side now, going to do the front RH too then get back onto outer body for the winter. Need to get the buck sitting tight on the windscreen then smooth and separate off the...

While playing with the new 3D printer I couldn't resist making this :)

started to work on something different for a bit, take a break from the big panel parts for a few weeks .. experimenting with the wishbones. My plan is to wet lay CF over a 3D printed PLA core, the core being mainly to help me keep the right shape. I have embedded ali tubes for the bushes and...

Front and rear clips tucked up tight in the shed to hibernate a few years till needed again ..

I've been using my extra time at home recently to make a bit more progress on the project, the front end is now done and moulded too :) demoulding the moulds from the buck was much easier this time, just popped off nice and easy, maybe the warmer weather. Had huge issues though with getting the...

Its been an exciting weekend, I took advantage of the warm UK weather and moulded the rear bodywork ! Bit of a mixed success. The thing I was really worried about was achieving a full vacuum seal on the 4-piece split mould, but in the end this was not too hard and went OK. I was also really...

been practising resin infusion before moving on the rear clam mould. Made a couple of flat panels that i'm gonna need later for the main body. This one is nearly 2mx1m and is eventually going to become the main rear bulkhead behind the seats. things i have learned; (1) getting a full seal on...

Last weekend was D-Day .. demoulding Day Mixed success .. managed to get all 4 parts of the mould off .. but in many areas the plaster of the buck broke before the mould release. The bits of plaster left on the mould seem to come off alright with hammer and plastic chisel so i think i'm ok ...

Thanks Chris, yes i think you're right on that just finishing off the 3rd part of the 4-part mould for the rear body. 1 more to go, then the moment of truth .. find out if the darn thing releases from the plug ! think i'm about a week away.

Thanks Michel, i'd planned to use PU foam instead of honeycomb, as its a lot easier for infusion .. and also a heck of a lot cheaper ! I don't intend to use it all over, just in local places where there are a lot of bending loads. Pretty much the whole body and structure will be made from heavy...