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Old 08-05-2010, 01:59 PM   #88 (permalink)
Dr. Jerryrigger
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Join Date: Jun 2010
Location: mass
Posts: 181

The Sh*t-Box - '99 Subaru Impreza Outback Sport
90 day: 27.81 mpg (US)
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Are you familiar with wood strip canoe construction? If not you should google it.

As far as crumple zones go; home fiberglassing is rather finicky, and it's impossible to really know how it would smash up with out smashing it up (and if you made a second, it would likely act differently). I would suggest going with a welded frame, and rather flimsy 'glass body.

How do you plan on getting a windshield for this? I have some experience with glass fabrication, and it would likely cost well over a grand to have that fabricated out of regular glass, and then who knows how much more to have it laminated. As for the side windows, you would have to find a company who can temper glass, and is willing to do a small order of a custom part. I don't now if such a company exists. It would be a different story if you were making 10,000 of these.
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