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Old 10-25-2009, 10:41 PM   #14 (permalink)
3-Wheeler
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AlienMobile - '00 Honda Insight
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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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