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Old 02-28-2013, 03:27 PM   #281 (permalink)
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I have to subscribe, because (1) the entire project is awesome and (2) I keep forgetting where I left off......

Great work!

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Old 03-05-2013, 03:39 PM   #282 (permalink)
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I've been working on the the inside and the back surface, and things are smoother than before (except the underside):



The inside curves are going to take a fair bit of hand sanding to get them smooth, but the rough shaping at least can be done with power tools.
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Old 03-05-2013, 07:59 PM   #283 (permalink)
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Built in wheel strakes! Not fair!

Looking good, Neil. Awesome progress, especially for winter work!!
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Old 03-06-2013, 12:32 AM   #284 (permalink)
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Yep, I pulled out all the stops! The underside has about 6" clearance at the front and it rises to about 11" at the back bumper.

Front and back wheel skirts - hinged in two pieces in front, naturally. The tall triangular slots on each side just above the end of the bumper are cabin air exhaust vents, so the air flow will (hopefully) get pulled out of the car, and it will help keep smooth attached flow. The inside vents are temporarily covered - you can just see the left side one in the 2nd photo above.
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Old 03-06-2013, 05:54 PM   #285 (permalink)
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Quote:
Originally Posted by NeilBlanchard View Post
The tall triangular slots on each side just above the end of the bumper are cabin air exhaust vents, so the air flow will (hopefully) get pulled out of the car, and it will help keep smooth attached flow. ..... you can just see the left side one in the 2nd photo above.
That is completely cool looking.
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See my car's mod & maintenance thread and my electric bicycle's thread for ongoing projects. I will rebuild Black and Green over decades as parts die, until it becomes a different car of roughly the same shape and color. My minimum fuel economy goal is 55 mpg while averaging posted speed limits. I generally top 60 mpg. See also my Honda manual transmission specs thread.



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Old 03-18-2013, 11:31 PM   #286 (permalink)
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Love this thread. Can't wait to see more. Keep it up!
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Old 03-19-2013, 09:14 AM   #287 (permalink)
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Fantastic project Neil. Do I see an electric planer in one of the pics beside the ROS? How did that work out ? I never would have thought of that. Thanks !
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Old 03-19-2013, 04:28 PM   #288 (permalink)
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It is similar looking to a planer, but it is a belt sander. It works okay for really rough stuff, but it tends to jump around sometimes. A power planer might work, but I don't own one to try it.

The dust collection on the belt sander and the random orbital disk sander are great; as very little of the foam dust escapes. Luckily, the dust is "heavy" and it mostly sinks down quickly. I do wear a mask when I am hand sanding, though.
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Old 03-20-2013, 04:14 AM   #289 (permalink)
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Power planers are used by many surfboard shapers to carve the foam cores. It takes lots of practice to not gouge it.
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Old 03-20-2013, 03:01 PM   #290 (permalink)
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It was warm enough again today to get a few more hours of work in on smoothing the inside:



A link to the photo album: 20 Mar 13 Progress Photos by NeilBlanchard | Photobucket

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