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3-Wheeler · 10-14-2010, 11:41 PM

After the epoxy setup, and the mold release removed, you can see the finished product.

Now it's finally time to cover the deck and sides with glass...

This may sound goofy, but now the flat underside looked, well, too flat, so it too is being built up in the middle with foam to allow a curved shape.

This curvature actually allows the air to flow further down the tail before reaching the dreaded 15° angle that starts causing flow separation, so I liked the idea creating the curved shape here.

Here is more foam being filled in along the bottom surface.

And now one night later, more panels being glued in place. Look at all those screws.

This is what happens to over 50% of the foam added to the tail extension in this project.... It ends up on the floor!!

And here is one of the light sockets before trimming.

Now adding lots of spackling to the bottom half. Using the light "shadows" is one of my favorite techniques to get things smooth.

The foam glue is setup, and now the screws can come out.

And this surface is now sanded smooth.

The light socket is being drilled and machined to the correct diameter for the light sockets.

After the socket holes are sized correctly, the sockets are glued in place with five minute epoxy.

At this point, the car has sat in the garage for 3-3/4 months or so, and notice nice the car looks with all that fine sanding dust on it.

The HV battery is being trickle charged back up to full strength, and much sanding is being done on the fiberglass finish, just to remove the rough edges.

And another view...

And a view of the underside...

One of the earlier posters, asked "what is the small hatch for"...

Well, now you can see that the large Honda hatch needs extra clearance to get past the extension when opening. And you'll notice that the dimensions are tight here.

Ah yes, were at the point in the build where we need to be concerned with electronics and wires and such.

Here is a picture of the license plate illumination light connector.

And the connector for the tail lights, which house:

1) run/stop bulb
2) amber blinker bulb
3) backup bulb

Jim.

10-14-2010, 11:41 PM	#152 (permalink)
3-Wheeler Master EcoModder Join Date: Dec 2008 Location: Southern WI Posts: 827 AlienMobile - '00 Honda Insight Team Honda 90 day: 80.05 mpg (US) Thanks: 101 Thanked 560 Times in 191 Posts	Final Stages of Build continue After the epoxy setup, and the mold release removed, you can see the finished product. Now it's finally time to cover the deck and sides with glass... This may sound goofy, but now the flat underside looked, well, too flat, so it too is being built up in the middle with foam to allow a curved shape. This curvature actually allows the air to flow further down the tail before reaching the dreaded 15° angle that starts causing flow separation, so I liked the idea creating the curved shape here. Here is more foam being filled in along the bottom surface. And now one night later, more panels being glued in place. Look at all those screws. This is what happens to over 50% of the foam added to the tail extension in this project.... It ends up on the floor!! And here is one of the light sockets before trimming. Now adding lots of spackling to the bottom half. Using the light "shadows" is one of my favorite techniques to get things smooth. The foam glue is setup, and now the screws can come out. And this surface is now sanded smooth. The light socket is being drilled and machined to the correct diameter for the light sockets. After the socket holes are sized correctly, the sockets are glued in place with five minute epoxy. At this point, the car has sat in the garage for 3-3/4 months or so, and notice nice the car looks with all that fine sanding dust on it. The HV battery is being trickle charged back up to full strength, and much sanding is being done on the fiberglass finish, just to remove the rough edges. And another view... And a view of the underside... One of the earlier posters, asked "what is the small hatch for"... Well, now you can see that the large Honda hatch needs extra clearance to get past the extension when opening. And you'll notice that the dimensions are tight here. Ah yes, were at the point in the build where we need to be concerned with electronics and wires and such. Here is a picture of the license plate illumination light connector. And the connector for the tail lights, which house: 1) run/stop bulb 2) amber blinker bulb 3) backup bulb Jim. Attached Thumbnails Last edited by 3-Wheeler; 10-14-2010 at 11:46 PM..