All,

I want to retract my previous statement about the weight of JC’s roof.

I sincerely apologize for stating that the roof weighed 4kg, this is incorrect.

The roof weighs 3.98kg – as JC keeps reminding me……..

Yours Sincerely

MJ

We got the roof out of the mold and all trimmed up, looks fantastic!

The roof mold has been cleaned and re-waxed ready for the next one to be layed up – another job for Sat.

Two doors are layed up, we’ll pull those out on Sat morning.

Both sideskirts are fully cleaned up and are ready for laying.

I also got some roll cage tube so the items that I want to add / change on the rollcage and to make the new rear chassis section.  It’s going to be a busy long weekend!

4kg total weight.

Nice!

The roof is all layed up, now to wait for it to set so that we can crack it out and see what it looks like in all it’s carbon glory!

The molds for the doors are now 100% complete too, can lay those up tomorrow night.

We also got one side skirt almost totally cleaned up, and have applied resin to the chipped area’s on the other mold ready to sand up tomorrow night.

The fun starts now…

The Carbon is draped over the mold in the pic above.

Below is after the resin has been applied!

This is the bad side, and its still looks so good!

We also got the door molds to about 95% finished.  Some final sanding tonight and they can be layed up as well.

After a 16hr day, here are the results:

The molds of both doors are complete.  The rear trim and the corner piece where the stock mirror once sat are both now incorporated into  the mold (the plan changed after we had made the basic door mold.)

The mold for the roof is off the car, has been all cleaned, sanded down and polished and has been bolted back together.  The roof is now ready to be layed up with some carbon.  One night this week we will lay up the first roof.

JC pretending to work as the camera is out. 😛

And then I was just walking along with the angle grinder and tripped over and then….

The roof came off…

With that gone I welded a few area up, linished off all the areas that used to mount to the roof and generally cleaned up bits that were impossible to get to before.

We’ve also almost finished cleaning up all of the rear molds, side skirts etc.  A couple of nights this week should see those complete, ready to lay up a full car next weekend.

Doesn’t sound like much progress for a long day, but we’re into that phase of doing all of the little, fiddly bits now and that takes a long time.

More after Tuesday night.

I’m putting some carbon and kevlar in selected area’s (like the roof)  for strength, looks yummy…

Just picked this up during lunch 🙂

Poor car….

Just to think we spent days and days getting it all perfectly clean, perfectly smooth….

The shots of the roof show the re-enforcement’s to keep it from flexing when we remove it from the roof and lay up the new roof.

Above, you can see the flanges that will allow up to get the mold off the roof, by pulling it apart.

Below, we have started on the remaining trim pieces for the doors.  The bit below is where the side mirrors would mount on a standard car.

Here, they have just been coated in gelcoat.  Next the fiberglass goes on top of this, making it look more like the roof pics above.

Here is the just finished mold of the trim that sits between the back of the door windows and the rear 3/4 windows.

More to come on Saturday!

The mold for the side skirts have now all been trimmed up and we’ve started on getting the main body molds all cleaned up ready to start laying up the first body.  A few more hours on those and they’l’ be perfect.

We continued on the roof, with the side sections now 100% complete, and the center section just requiring one more layer over the re-enforcement that we have added.

We’ve got lots of the molds ready to go now, so hopefully by the weekend we’ll have layed up our first final product!

Will have pics of all this after tonight…

The roof has been leveled out as much as I’m capable of (or as much as I can be bothered doing!).  The roof used to have a sunroof, so we spent quite some time getting it all perfect.

Now that that is done, we’ve started laying the glass.  The mold will be in three parts, hence the flange for the join sticking up into the air.

Tomorrow night we can remove the support for the fence, and lay up the other part of the roof, and the A-pillars.

Makes a good workbench for fibreglass work…

Looking very good!

Nice and shinny straight out of the molding process.

A clean and wax, and she will be even better again.  Happy.

The first 3 layers of glass are on the skirts.  Plus another pending project in the back ground.

Some reinforcements and 2 more layers and they will me done!

Also layed up some flat bits for the upper part of the door vents.  This will make more sense in the next week when we fabricate it.

Started by polishing the form board.

Then put PVA on it, followed by gelcoat.

Then two layers of glass and leave it to set.

Here it is, all set, removed from the board and turned over to show the finished side.

The side skirt bucks are painted, polished and have the PVA release agent applied.

Nice and smooth and shinny, ready for fibreglass.

My partner in crime on this project is away for a few days, so in going to sleep – I’m shattered.

The roof is so very close to being perfect.  Hopefully this is the last round of filling and sanding.  I do keep saying that though don’t I…..  The joys of having had a sunroof.

The roof scoop is in the final stages as well.

Another night of filling and sanding, the skirts are just going to need one final sand down tonight, and they should be perfect.

The skirts are off the car, and the car has been rid of all excess metal.

The roof is very close too, probably one more round of filling and sanding to go.

It looks so phatt undressed!

Hoping to have the roof and skirts 100% finished tonight.  We’ve also got  a few pieces to make for the doors, hopefully can get them molded tonight too.

No, that kind unfortunately

The sideskirts are coming on very nicely, should have them almost complete by the end of tomorrow night.

The roof is coming along well too, Probably needs another layer of spray filler and a sand tomorrow night.

More skirt detail

More tomorrow night!

With the new rear end, we need some new brake lights, so I machined up a prototype.

Here is the finished prototype, with lights on.

Again, from further away.

This is what it will look like with the brakes off.  The cover is clear, with a black background behind it.

If they look nice on the car, I’ll be machining some more…

I was just picking the grinder up to move it, and then…