Fabbing custom body panels?

[Wrecked944]

I stumbled on this via the MAKEZINE.com blog section. Looks like some DIY guys fabbing their own body panels...

http://www.6park.com/enter7/messages/gvk21098.html

They seem so to be converting an Acura NSX to a Ferrari F50 body style using only a diecast ferrari as a guide. I don't plan to convert my precious 911 to an F50, but I think it is a pretty cool set of skills. So may I ask if anyone can explain how these guys are doing this project? The website is not in english and so it is just a set of tantalizingly interesting pics. Looks like they are using some sort of foam (?) to make a positive plug and then spraying (?) chopped fiberglass over it and then somehow smoothing the fiberglass (or perhaps making a negative mold?) and painting. And it isn't terribly clear how they managed to attach the new panels to the chassis. So can anyone explain this process to me? The end result was impressive.

[RickM]

This was posted before. It might have been in English....not sure. I'll try to search.

[Tim Hancock]

I do not know how they are doing it, but I have built aircraft cowlings and others have built entire planes out of fiberglass. One basic method is to carve/sand foam blocks to shape, then layup fiberglass cloth layers over it with epoxy or resin (takes for ever to sand fair after drying). Another way is to bend and form wire mesh close to the way you want it, then plaster over it, then lay-up fiberglass over it (lots of work).

No matter what way you do it, there will be a lot of sanding going on which I hate doing.

More advanced ways include making a mold then laying up or vacuum bagging the cloth in the mold. You can even get fancy and apply gel coat to the mold then the glass.

The chopped glass sprayed into a mold is quick, but chopped glass is not nearly as strong as woven glass therefore it must be applied way thicker and therefore is much much heavier.

All of the above methods can and have been done by DIY guys in garages and shops for years.

[tt_targa]

That was an interesting project.

I bet in the US, it would be cheaper to sell the NSX and buy a real one.

The glass job looked really good.

[Ove]

Wow, that's a LOT of work to try to turn a nice car into something it will never be...

Take a look at www.gunnarracing.com to see how they make custom rear fenders on their "RATT RSR".
(Go to completed projects, RATT RSR, October 1 2003 update)
They also use some kind of foam.

[Yellowbird RS]

lot of work for a poor result

[kycarguy 935]

Looks like they have alot more questions and answers on that website..lol...it could just be my browser???..lol

兄弟们,睁大眼睛,看NSX是如何变成法拉利F50的(100pic)[图片]

[Wrecked944]

Originally posted by Tim Hancock
All of the above methods can and have been done by DIY guys in garages and shops for years.

Brilliant! Thanks for the info. I've never tried that stuff but it looks pretty cool. May I ask if there is a special type of foam that is used to create the plugs? I've never seen that stuff advertised in Eastwood (i.e. my primary source for body work knowledge). And how do they form the foam? Is it wire cut, sanded, knife cut, etc? I always thought car designers used some sort of special clay to build prototypes?

And do they sand those things by hand? I would think that much sanding would almost require a power sanding rig.

[Tim Hancock]

If you use epoxy, instead of regular resin, you can use blue foam like is used as house insulation. You can saw/cut/sand many foams using various abrasives. It takes alot of sanding of the finished hand layed up type of parts to end up with the finished product (I hate working with glass as I HATE sanding).

Aircraft Spruce and Specialties sells other types of special foam also (check their website catalog under composites and you will find nearly every type of material you could ever need for doing all types of composite work).

PS Did I mention I HATE SANDING!!!!!

[Biff]

I quess you have to hand it to them...that's quite an undertaking and they certainly are motivated??