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Old 08-01-2012, 02:31 PM   #31 (permalink)
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This is superb! I haven't been on much, but I remember when you started designing it - gives me some motivation to work on my EV conversion for sure!

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Old 08-10-2012, 03:15 PM   #32 (permalink)
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Awesome!
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Old 08-10-2012, 11:06 PM   #33 (permalink)
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I'm back from a week off, so I'll get a little done. I've got a paying drafting job next week so there will be another brief pause...
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Old 08-13-2012, 10:32 PM   #34 (permalink)
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I glued another layer and then I had to cut another 8 sheets, so as to have all the parts for another 3 layers. If I cut 6 more sheets I can glue up another 6 layers. So, that would be another 18" of the car.

As I mentioned, I'm working this week, so pictures should be possible next week.
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Old 08-13-2012, 11:36 PM   #35 (permalink)
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This is a fabulous thread! I love the fact that you are building a 100% DIY EV. Can't wait to see this thread evolve!

Great project!
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2000 Honda Insight MT Silverstone Metallic #95 (CAN) 131K mi. 81.7 Lmpg
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Best Trip : 111.8 MPG (US) | 134.3 MPG (Imp) | 2.1 L/100Km | 47.53 Km/L

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Old 08-20-2012, 09:07 PM   #36 (permalink)
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I've glued up another 6" and I've now got a nice random orbital palm sander, that makes a much smoother surface than before. I still need to do a lot more shaping inside the hood area before I glue any more layers to it. Here's pictures from today:

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Old 08-27-2012, 08:42 AM   #37 (permalink)
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I now have a 24" deep piece and a 20" deep piece -- they are held together with four 1/2" dowel rods for the moment. I have to nearly finish the shaping inside the motor bay while it is accessible from the back before I glue these together.



Here is the front 44" resting on the ground -- looking kinda' like the CarBEN EV5 Ranch?



Okay, now in the proper orientation:



As a reminder, here is the latest animated video of the SketchUp model:

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Old 08-27-2012, 07:33 PM   #38 (permalink)
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Question for those folks with experience shaping foam -- what works for smoothing small-ish concave surfaces?
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Old 08-27-2012, 09:49 PM   #39 (permalink)
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Looking good, Neil.

A guy at work said that he saw the tv show you were on.
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Old 09-02-2012, 10:26 PM   #40 (permalink)
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I added 4" to the second piece (photos to come), and I've now glued up another 6" (sections 11-13) for a total of 4'-6" of the front:



The gluing is slower now because the sections hang off my table too far (as you can see) -- I need to make a table the is ~6'x6' for the middle part of the car. All 4 battery bays have started -- the outer 2 extend just 2" forward, and the center 2 extend 6" forward.

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