Good answers.
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And the only reason why I used this new rolling chassis was that after selling the brand new cab, hood, bumper, skirts, etc., it was actually cheaper than building it from scratch. And it saved an estimated 6 months in our build time.
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Our hyper aerodynamic cab is built entirely from carbon fiber and foam. It is shipping today from California and we plan on having it at my shop next week. We'll install a chrome-moly safety cage once it gets here. But basically the cab is a safety cage surrounded by a hyper aerodynamic super lightweight cab envelope.
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I'm the sort to overthink the implications before I jump into anything; so I don't have a new truck to show...
But that said, I'm a big fan of formless construction. I used to do whole buildings that way. I think in terms of [probably] laser-cut sheet metal polygons that seam together into an ellipsoidal shape.
[geodesic motorhome.jpg]
Have you thought about Local Motors and microfactories, or the Maker movement in general as an avenue to low-volume production?
Is the whole thing caged, or just the driver position? I've always thought a good Beta test would be to enter the vehicle in various races it might qualify in, run it through the tech inspections of the various sanctioning bodies, and then drop out with 'engine troubles' at the starting line to protect the investment.