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Old 10-19-2009, 12:07 AM   #11 (permalink)
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Originally Posted by NeilBlanchard View Post
I nominate this for the Mod of the Month!

(I installed CoolIris so I could use it on the Picassa page...)
Hi Neil,

I read your entire thread, and learned a few more techniques that I can look into next year, when the weather gets warmer.

I thought the foam under the hood seam to keep air out was a nice touch.

Keep up the good work, and keep posting your progress as it makes for interesting reading.

Jim.

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Old 10-19-2009, 10:19 AM   #12 (permalink)
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Originally Posted by 3-Wheeler View Post
Hi Christopher,
All of the wood supports mounted to the car have been epoxied to keep the water out. The only weak area is were the wood screws hold the panels onto the car. Water can seep into those areas. Only time will tell how this holds up.

I do have a motorcycle fairing with 115,000 miles that is constructed in a similar manner and still looks good, but it is not mounted underneath a car body either. However, the fairing still gets rained on just like the car, since I typically ride it rain or shine when it's warmer, such as this summer when working on the smoothing panels.

Jim.
Guess you'll find out how it'll fair until you run with it on 'til spring is back again.

I noticed too, with silverinsight2's mention of your Picasa web folder, there's more pictures there than were shown off here, showing yet additional fairings. LOTS of work went into this, and if you are getting your additional 7mpg, at least you've something tangible to show for it.

I'll have to look at my underbody pictures I took the summer before, and plot and scheme how I'll attach similar fairings. Fairings and living in the snow belt have kept a few of us a bit wary of going too aggressive with smoothing out down below -- because of concerns about snow and ice packing, or how it could pack more sand/salt crud used to melt it in on the underside where we'd prefer it not to be.

Please be sure to update how it performs after winter's through.
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Old 10-20-2009, 12:14 AM   #13 (permalink)
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Quote:
Originally Posted by ChrstphrR View Post
Guess you'll find out how it'll fair until you run with it on 'til spring is back again.

I noticed too, with silverinsight2's mention of your Picasa web folder, there's more pictures there than were shown off here, showing yet additional fairings. LOTS of work went into this, and if you are getting your additional 7mpg, at least you've something tangible to show for it.

I'll have to look at my underbody pictures I took the summer before, and plot and scheme how I'll attach similar fairings. Fairings and living in the snow belt have kept a few of us a bit wary of going too aggressive with smoothing out down below -- because of concerns about snow and ice packing, or how it could pack more sand/salt crud used to melt it in on the underside where we'd prefer it not to be.

Please be sure to update how it performs after winter's through.
Hi Christopher,

I plan on adding more pictures of the other panels to this thread, so those who are interested, do not have to look at the other posting on Google.

You are right, in that the snow, and it's affect on the panels is a concern. More specifically, those hard, crusty, pieces of hard ice that drop off the cars could *really* cause a problem with these panels. The panels are plenty strong for high air speeds, but no match for a carefully placed 'snow crusty'.

I also have to make a fender-well snow guard for the rear wheels, to keep snow from packing in that area, similar to the front. With the weather getting colder, it may be a bit tough, but we will give it a try.

Jim.

Last edited by 3-Wheeler; 10-20-2009 at 02:40 PM..
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Old 10-25-2009, 10:41 PM   #14 (permalink)
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--- Drivers Side Smoothing Panel ---

Wood strips are fiberglassed and attached to the underside of the car.


Foam blocks are glued to the wood sub-structure.


More blocks are glued in between the edges of the wood pieces.


The entire shape is almost roughed in.


Now that the structure is strong enough to support it's own weight, it is taken off the car.


The rough edges of the blocks are tapered and smoothed in preparation of adding glass cloth.


Back on the 'smooth' side of the panel, more foam is added to fill-in a low spot.


After much blending of the foam, glass is added and wetted out with resin.


Now the wood, foam, and glass can be seen in this picture.


This is the 'smooth' side of the panel after glassing and adding a small amount of glazing.


And another view of the smooth side of the panel.


The panel mounted on the car.


Jim.
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Old 10-26-2009, 02:15 PM   #15 (permalink)
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Holy crap. Are you going to bring this to the green grand prix next year? This could give this year's winners a run for their money. Going to boat tail this? You're pretty much going all out already....

Very nice work. Kudos.
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Old 10-26-2009, 11:32 PM   #16 (permalink)
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Holy crap. Are you going to bring this to the green grand prix next year?
Hi Wonderboy,

Where is the green grand prix?

I was at Hybrid Fest in Madison last summer. Of course the car was in the garage, and I rode the motorcycle, which currently barely gets the same mileage as the Insight.

When the weather gets warm next summer, I doubt the motorcycles 79 mpg best will be able to keep up with the car.

I think the Grand Prix guys can kick the snot out of my 'normal' driving style, since I rarely pulse and glide. However, 43 mph seems to be my favorite speed for driving to work on old country roads.

As for boat-tailing; yes I can see the day coming when I would try something like that! It goes without saying that six months would be reserved for sanding/glazing/priming/painting the fiberglass to get that 'smooth' finish.

Jim.
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Old 11-04-2009, 11:26 PM   #17 (permalink)
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Just found this thread. WOW. Impressive work, Jim!

EDIT: the GGP is in Watkins Glen, NY.
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Old 11-05-2009, 02:54 PM   #18 (permalink)
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Just found this thread. WOW. Impressive work, Jim!
Thanks Metro!!

There are a few more pictures to post soon.

Jim.
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Old 11-05-2009, 11:46 PM   #19 (permalink)
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very impressive indeed. what did you use the GREAT STUFF FOAM for?
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Old 11-06-2009, 09:30 PM   #20 (permalink)
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What are you using to glue the foam pieces of the puzzle together?

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