[CigaR007]

This is my vision for the CR-Z. The front of the car is pretty straightforward, aero-wise. The rear is just a concept. I have no idea if it would help.




Here is the progress :

Preparing the grille fascia with aluminium foil



Insulation foam applied on grille opening



Foam is then carved to desired shape



First layer of fibreglass is applied. This was my first attempt at using fibreglass. I used a polyester resin and it was a mistake. The expanding foam deformed in some spots and the surface became very uneven. Polyester resin is a no go with expanding foam. Switched to epoxy resin for the other layers. Another no go would be applying the fibreglass vertically...I paid the price for not wanting to remove the bumper. Lots of lessons to learn from !



The cost for these mistakes ? Lots of body filler and elbow grease to level the surface...Another mistake in this photo, I somehow miscalculated the epoxy and hardener ratio (5:1). This layer of epoxy was not as hard as it should have been. It looked nice though



Lower grille opening was cut out. Some body filler and sanding. Two layers of fibreglass mat with the correct epoxy-hardener ratio this time. The result was pretty good. Slowly learning...



Onto trimming the unnecessary fibreglass mat. This turned out to be another lesson. Try to keep fibreglass mat to the smallest size possible, without compromising the structural rigidity. Trimming was a tedious process.



Grille block from different angles :








View of the front end of the CR-Z without the bumper. Seems to be pretty optimized in terms of ducting and controlling the incoming cooling airflow.




Cheers !