Springfield Flyer.

[tauruck]

I've been working on shaping the nose for the liner.
My original idea to build the plug using ribs and cladding it with styrofoam
seemed like a good idea at the time but I should have gone the more expensive route
and had someone CNC the part from a solid block.

Sofadriver Mike is constantly on my mind as I work and even though composites are
my day job his project impresses me more and more.

I put a layer of glass over the polystyrene and figured I'd just add a thick layer of fairing paste
and sand out the high spots.

Sounds simple and maybe on a smaller part it should be. This part is driving me nuts.

The high spots are too thin and sanding finds me going right through the epoxy/glass layer.
You can't use any aggressive type tool because the nose moves all over the shop and you just go right through the thin skin.
I'm getting there slowly but it's a PITA.

The trick will be to get the same profile on the right hand side. I've only almost finished the left but it's wavy as heck.

I'll post pics once the PC is repaired and I can download pics.

[Buickguy3]

    Mike,
   You are living my worst fear of working with glass or carbon. I'm always looking for an easier way out. Looking forward to seeing your finished nose.
    Doug 

[tauruck]

Doug, I think I'm winning.

I used the new HS spray filler from Spies Hecker yesterday and things look pretty good.
My sponsor KansaiPlascon is the national agent and the products are the best I've used.
Been at my job for a long time and the quality is unbeatable. Makes the task so much easier
when you use top line materials.

Thanks to Susan Theron, my liaison the job just got a whole lot better.
The tech guy says they'll paint the car and I know it's going to be perfect.

[tauruck]

My PC came back from repair. They charged me a whopping $12 and nothing's changed. It still doesn't work so it's going back.

So still no pics. :x :x :x

I have been busy though and have made good progress on the nose piece.

[wobblywalrus]

Grab any kid you see walking down the street, give them a big bowl of ice cream, and they will show you how to anything you need on their phones, Kindles, etc.

[tauruck]

My ''kids'' are all grown up, busy and have their own stuff to take care of. I'll get it sorted today Bo.

[Buickguy3]

  I wondered why it's been so quiet on your end.
     Doug 

[tauruck]

I found out the PC repair was good but the big LCD flat screen is also screwed.

The hits just keep on coming.

Liner related stuff is all good though. A small disruption but we'll get over it.

[sofadriver]

I've been working on shaping the nose for the liner.
My original idea to build the plug using ribs and cladding it with styrofoam
seemed like a good idea at the time but I should have gone the more expensive route
and had someone CNC the part from a solid block.

Gee, did I forget to mention all the screw-ups I made,  all the holes I burnt thru the glass with a belt sander  and what a gigantic PITA building the body was in my build diary?

 

[wobblywalrus]

Laminated sheets cut on laser printers and glued together might be the way our kids do it.

[tauruck]

Mike, you're on my mind constantly.

Remember, this is my day job and I'm not having fun.

Any king of manly pressure used with any tool other than the palm sander makes holes.

I should have used more than the two layers of glass I used on the plug. Epoxy is expensive so I skimped
on material but it turned out to be more costly taking the short cut.

I'll be using six layers on the other three body sections.

These are large parts. The nose is about 10ft long and I still need to shape the right side to match.

The symmetry on your body work is awesome and the guys have no idea how hard you worked to achieve it.


Bo, there's only one way to do this shaping if you don't have access to 5 axis CNC equipment. Ask Sofadriver.

[tauruck]

MY PC is working. I don't know how the universe works but the guy that built it on 05 called out of the blue.
He took over the repair and did all sorts of upgrades in return for a small welding job.
Thanks Greg.


Working on the "hand shaped" nose and here are some progress pics as the process occurred.
Sanding the left side trying to use as little pressure as possible.
Some black guide coat to help.

Second pic is the right side that will need mirror imaging.

[tauruck]

I wasn't winning so I loaded the spray gun with Spies Hecker HS primer.

The difficult part was positioning the nose on its side and keeping it there.
The Dodge thing just wants to flop over and lie on its back.

I used a Kilo of filler. Had I been using the cheap store bought stuff I'd have used five times the amount.
This paint goes far and is definitely the best I've ever used.

[tauruck]

Some other angles of the filler job.
Lots of low spots.

[tauruck]

I just kept putting on coats until the paint was used up.
You could probably coat a complete car with this stuff.
It really goes far and fills like gang busters.

After the filler had dried I put on some finishing black to use as a guide coat.