Large challenge

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janeh

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This isn't boaty but does require the skills of practical people and possibly fibre glass know how.

If the post is in an inappropriate section, please say so and I will delete it (if that is possible - or ask the admin to delete it)

I am helping a school's D&T department. Their latest project is to design and make a full scale model car. Not quite up my street of knowledge.

I need ideas.
My initial ideas were to buy a scrap car, and use it as a form for fibre glass. Then jig the panels together with wood (kids need to get in and out of the car)

Or, use polystyrene and a big wire cutter? And then laminate the poly with something to give it strength from dents etc?

They have a year to build.

Any ideas?
Thank you
Tra la
 
Chicken wire and wood former. Then clad in papier mache, GRP etc.
Of course, if the model is supposed to be of a real car, then your first idea could work. You would have to be very careful that the shape was such that the car can actually be got out of the mould. No returns, etc.
 
Jane, you could even use a real car as a former for the chicken wire.. it would release from the car a lot more easily than a completely rigid fibreglass shell....

PS... what a great project... something really stimulating and challenging for the kids!
 
Purchase, modify and repair any old fibreglass plug from kitcar/hotrod use... and use as a base for modifying it to what you require.

I'd caution against polly as it really just ends out to be a real mess.

Could also pick up junked fiberglass bodies quite cheaply. Nova comes to mind and then cut and shut as they desire!
 
Another thought

How about if we built in a similar fashion to strip planking as John Shuttleworth does?

What material could we use for the strips?
I thought I read once that there are foam type strips? Epoxy over, remove the plywood forms and voila, light strong car?

n'est pas?
Tra la
 
Hi Jane, an excellent project, as has already been said! I wish more schools & groups working with kids would encourage them in big, exciting projects like this!

I used to work for a small sports car company, so I'm pretty familiar with most of the processes involved in building one from scratch. When you say a "model" car, does that mean that even though it's full-sized, nobody will sit in it to drive it? Does it actually have to move under its own power?

If not, the fastest an cheapest way to get something that looks roughly like a body would probably be to get a scrap car and cut most of the body off it so you're just left with the wheels attached to the floorpan. Then get a load of 2-pack foam like this stuff:

http://www.cfsnet.co.uk/acatalog/CFS_Catalogue__2_Part_Polyurethane_Foam_Liquid_415.html

mix it up according to the instructions and pour it all over the floorpan, having made up some protectors to cover the wheels. As soon as it has set, it will look like a huge meringue with wheels on. Get the kids hacking at it with whatever comes to hand - saws, bread knives, surforms, etc until they have sculpted a shape that they like.

Then paint catalysed gelcoat resin all over it and let it set.

Once that's done, just paint it and paint the windows gloss black. It won't be especially strong but it will be quick and look something like a car.

You can do the same if it IS supposed to work, but it's a lot more involved.

Send me a PM if you want to discuss it further.

Good luck!
 
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