Springfield Flyer.

[tauruck]

Nose floor tray progress.

The foam core was bonded in yesterday.
This morning I got the glass/epoxy layers down.

[tauruck]

After consolidating the glass as best I could I put a layer of peel ply down ready for vacuum.
I hate vacuum bags but it's part of the job.

It's a thin skin because this pan needs to be cut for wheel holes, pneumatic jack openings and jacking points.
Once all that is done I'll beef it up.

[tauruck]

The nose floor tray is out of the mould and loosely mocked up under the liner.
It needs to go back 2" because it fastens to the mounting pegs that hold that and the next tray.
I'll drill it later.

After I secure it in position I can mark all the cutouts for tyres, the pneumatic lifts' bases and around the dolly opening.

I'm not sure of the correct steering angle so I'll have to guess unless someone can tell me?. Thanks.

[tauruck]

The 1st front wheel tub has Basalt Fibre in it and it will get beefed up when I get more resin.
Second rear tub is also 50% done.

[tauruck]

Diffuser in the mould.

I made a Styrofoam part to dimensions just to check fit and clearances.
That was good so I got the mould prepped for the Glass/Polypropylene honeycomb sandwich panel.
This honeycomb is very good especially when used with a good resin system. It's been sitting against a wall in the house for a long time.
I have many sheets of 10mm but this is 20mm and I had only one.

Base went great and after I got the vacuum bag off I let the first side cure out in the son. Got up to 60*C for about 4 hours.
This high end epoxy needs a good post cure but once the whole part is assembled I'll get it done.

This is a cut & fold technique that is easy to do and it works well.

Today I'll lay up the second side.

[tauruck]

Composite honeycomb diffuser panel is cured and out of the mould.
I precut the glass, carbon and peel ply to width mostly.
The 300mm I saved on the three layers made up a fourth layer. Some guys get that extra wet and throw it. I cut and save.

Cut and fold tomorrow.

[tauruck]

Got the itches today.
Rookie mistake from 20 years ago.
I had to use the circular saw to cut 90* angles in the composite panel.
I was too excited to dress properly.

The top of the diffuser and one side are clamped with filler and curing.

I pulled the panels to get 90 which is a good thing because it means the outer skin is intact.

[tauruck]

I have a big part of a diffuser. Short 20" because my mould wasn't long enough so a splice is coming up.
The new section is being laid up later.

The part is solid, square and fits the chassis perfectly.
After it gets lengthened it will have to be bonded to the floor tray I haven't made yet.
I knew this car was long but only got a true perspective when I was lying on the creeper fitting mounting pucks to the front floor.
This car is HUGE. Dang!!!!.

Some images of the diffuser.

[tauruck]

A few more.

[tauruck]

I made a tyre pening marking tool from some scrap Aluminium.
It's got a hole for the axle, a 90* bend and a hole for a white Sharpie.

Cutting small to start.

[WOODY@DDLLC]

Mike, measure with laser, mark with chalk and cut with (sharp) axe! 

[tauruck]

My laser is so old school it only measures 90 degrees.

I'll get it figured out with what I have. Africa buddy.🤣🤣

[tauruck]

The diffuser extension is clamped and curing.

I used cut and fold on the composite honeycomb panel.
Routed 90* into the one surface down through the honeycomb but not into the backing panel.
Epoxy is awesome. Just laid the part on the edge of the mould face down and used the heat gun.

It folds better than paper.
Put Epoxy with a filler mixed in into the void and clamped it square.

[tauruck]

Engine cover progress.
Under direction from my main mentor Tom Burkland I've changed my engine bay braces 3 times.
I promise you I never thought the cowl would come even close!!!!.
Praise the Lord. 🙏🏻🙏🏻🙏🏻✝✝✝Another miracle arrived.

The photos don't do it justice but everything will clear with "room" when it's finished.
Thank you Tom for sticking with me and sending all the emails and messages.

[SPARKY]

Mr Tom B  has worn that cap many many times over the years!!  Thank you Tom B!!