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Mock up of the form for the rear diffuser/air straightener. As with the other pieces, will get turned into carbon.
https://farm9.staticflickr.com/8669/...66605cdf_b.jpg https://farm8.staticflickr.com/7507/...1ff3b399_b.jpg https://farm8.staticflickr.com/7525/...2bf9c06b_b.jpg Beginnings of the spoiler uprights. (we went through about 50 versions of this shape before settling on the one we liked...) https://farm8.staticflickr.com/7558/...23ba809b_b.jpg https://farm9.staticflickr.com/8673/...67e77df3_b.jpg Cut in steel on the plasma for now. These will eventually get waterjet cut in aluminum with machined detail. https://farm9.staticflickr.com/8563/...9e462518_b.jpg https://farm8.staticflickr.com/7569/...cb27017b_b.jpg Starting to look a little racy... https://farm8.staticflickr.com/7560/...d2e7ec7a_b.jpg |
thoroughly enjoying this build.
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That rear is outrageous!
Awesome stuff. |
Wow !
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With the shapes dialed in, we needed to digitize the surfaces to both make the slight changes and additions we wanted and so that we were able to mirror the flares for the passenger side.
The guys from Exact Metrology were happy to assist in the process. Using both the Romer arm and Surphaser, they were able to capture the detail and parts of the vehicle we would need for the next steps. Science! https://farm8.staticflickr.com/7508/...70b85b95_b.jpg https://farm8.staticflickr.com/7529/...e605263b_b.jpg https://farm8.staticflickr.com/7470/...9de9e564_b.jpg https://farm9.staticflickr.com/8670/...bd4aca38_b.jpg At this point, the file they captured was then used as a base for us to generate the final surfaces. Wile forming everything by hand and scanning to 3D is a great start, the ability to form a 'clean' surface model in 3D would allow for a perfectly smooth surface. It would also afford us the option to break each surface into parts and add all the structure needed for it to become a suitable plug for a mold to be made. It was also way more efficient to add details at this time in the computer like the fastener recesses and vents. Original scanned file: https://farm8.staticflickr.com/7522/...4d88db57_b.jpg 'clean' surface/plug file: https://farm8.staticflickr.com/7521/...5967b06a_b.jpg https://farm8.staticflickr.com/7517/...8cd5aa5a_b.jpg |
With the 3d work complete, the files were sent off to be machined (due to the size we couldn't do it here)...more on that later!
The car could then be removed from the table and the fab work could continue. Since we were now able to get under the car, we set about on the 180 degree headers and fabbing up the stainless exhaust!! https://farm9.staticflickr.com/8609/...9e0a8fce_b.jpg https://farm8.staticflickr.com/7466/...b6bf1211_b.jpg https://farm8.staticflickr.com/7570/...937b8a3d_b.jpg https://farm8.staticflickr.com/7567/...4a93de40_b.jpg https://farm9.staticflickr.com/8651/...0e16d353_b.jpg https://farm8.staticflickr.com/7550/...45c982df_b.jpg |
ok, now your just showin off.
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Can we get a video of this beast running?
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Yesh those 3d scanner things are great - I got one from Harbor Freight recently that I've been using. :gitrdun:
Where did the CF nose come from ? who does your custom CF work ? Can't help thinking I'd rather have the engine 2" lower than kick ass 180 degree headers though. Really appreciate you guys sharing the details. So beautiful and so much to learn from. |
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Awesome stuff. |
What size tires are those?
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Each build more impressive than the last.:hairpullout:
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Ok really??? This is getting out of hand :twak: there needs to be a disclaimer before entering this thread from now on!! :thankyou:
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:thankyou: Wil. |
wow....just wow
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I just dont understand. That undercarriage is just off the charts. What i dont understand is 1/2 the stuff i see under there i've never seen before, i'm like "wtf is that?" and then, "ohhh, wow".
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THE coolest machine I've ever seen.
That exhaust system is unbelievable. |
There's absolutely nothing I don't like about this build. You could throw an AMC Matador body on it and I'd still think it was cool!
A friend built a slant nosed Porsche in the early 90's with a 350 SBC in the back and he built a similar header system for it......still one of the coolest sounding SBC's I've ever heard. :thumbsup: |
I go into withdrawals when I don't get daily updates on this build... :hairpullout:
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Some more pics!
We elected to house a couple of coolers in the rear quarters for the rear end cooler and trans cooler. These would end up sitting behind the rear flares. https://farm8.staticflickr.com/7503/...092fc636_b.jpg https://farm8.staticflickr.com/7540/...4d249912_b.jpg https://farm9.staticflickr.com/8647/...41bca881_b.jpg[/url] The rear mesh pattern and light surrounds being cut: https://farm8.staticflickr.com/7546/...f3cd03cb_b.jpg https://farm8.staticflickr.com/7492/...90d404e5_b.jpg https://farm8.staticflickr.com/7490/...fb52bef4_b.jpg https://farm8.staticflickr.com/7473/...7f67d60e_b.jpg Rear firewall: https://farm8.staticflickr.com/7484/...aff44b42_b.jpg Being a race car, it would be pretty critical to get air into the cabin for the driver. As such, a detail we knew we wanted from the start was the roof scoop: this feeds down through the roof to directional air vents. https://farm9.staticflickr.com/8595/...02e28208_b.jpg https://farm8.staticflickr.com/7541/...7a557093_b.jpg Exhaust tip bezel: https://farm9.staticflickr.com/8663/...4a06ecf3_b.jpg https://farm9.staticflickr.com/8646/...58b13db9_b.jpg |
You guys should consider a build book on this car.
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I would definitely buy a copy of that!
This build is way too cool! The Roadster Shop build threads are the primary reason I started lurking on this forum. You guys definitely knocked it out of the park on this one. |
Some under the hood action and the mock up of the intake ducting coming in from the front opening next to the main headlight.
Lots of 'packaging' to consider as there would be a large air box behind the radiator evacuating air through the hood. All has to fit between the cage downbars, next to the motor, ahead of the motor around the cantilevered suspension and all under the flat, non-cowl hood. https://farm8.staticflickr.com/7577/...357d9e9d_b.jpg https://farm8.staticflickr.com/7556/...527d5c21_b.jpg https://farm9.staticflickr.com/8604/...ee62c799_b.jpg https://farm8.staticflickr.com/7578/...cd88c6ec_b.jpg https://farm8.staticflickr.com/7505/...a168855b_b.jpg Nothing like cutting into a nice fresh "only one available right now" carbon hood.... https://farm9.staticflickr.com/8602/...260ae1cd_b.jpg https://farm9.staticflickr.com/8649/...160bc8dd_b.jpg https://farm8.staticflickr.com/7476/...6bf1037f_b.jpg https://farm8.staticflickr.com/7492/...18edea3d_b.jpg https://farm8.staticflickr.com/7476/...3b346f49_b.jpg https://farm9.staticflickr.com/8588/...d7192222_b.jpg https://farm8.staticflickr.com/7557/...02330667_b.jpg |
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https://farm9.staticflickr.com/8584/...1cafb2ae_o.jpg |
Building the intake airbox
https://farm9.staticflickr.com/8561/...43a131d1_b.jpg https://farm9.staticflickr.com/8662/...88a7a80b_b.jpg https://farm8.staticflickr.com/7517/...bbf7db5e_b.jpg https://farm8.staticflickr.com/7492/...cf9591c9_b.jpg https://farm9.staticflickr.com/8575/...53450880_b.jpg We decided to switch to the orange flex hose at this point for looks instead of the solid tube. https://farm8.staticflickr.com/7477/...ca526d24_b.jpg Underside of the intake box has drop out provisions for the filters https://farm9.staticflickr.com/8637/...357b7666_b.jpg Since we were going for a more clean contemporary feel on the outside, we dispensed with the stock trim and made a clean insert piece to meet up to the new grille mesh https://farm8.staticflickr.com/7508/...28355406_b.jpg https://farm8.staticflickr.com/7522/...27be1c63_b.jpg https://farm8.staticflickr.com/7543/...ab094da9_b.jpg |
From concept to fabrication to finished product, your stuff is flawless all the way through. I would pay money to spend a day with one of your sheetmetal fabricators.
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I can't even begin to comprehend the planning it takes to do BEFORE doing any of the actual building on your builds. Never mind the actual building of the car.
Amazing guys. Another home run! |
Alright, I know you guys are experts at what you do. However, you guys still have to be nervous cutting into a hood like that...right?
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OUTSTANDING WORK!!!!! I love the headers or header. This car is amazing. :confused18:
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The exhaust system on this thing should be hanging as art somewhere. Unbelievable workmanship on the whole car. Thanks for the behind the scenes on this build!
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Lost for words.... again! :thumbsup:
One thing I would have liked to see you guys do on this car is your interpretation of the classic 70's racing BBS wheels and even more so the brake cooling fans bolted on to them. http://www.greenwoodcorvettes.com/Ra...sisfrtleft.jpg But then again, I saw how you made the wheels for this, your idea and execution is 100000000000 time better... :thumbsup: |
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Thanks for all the comments!! :thumbsup: |
Well, new year, new pics!
Aluminum inner door skins: https://farm9.staticflickr.com/8618/...2bd2cc5e_b.jpg https://farm8.staticflickr.com/7550/...b32da0cb_b.jpg From where we left off: at this point the car is in a position where it could be broken down and the shell sent out for powdercoat on all the interior and inner surface/structure. Some CNC action on the E-brake. We engineered this to be an upright style lever for more aggressive use which can also be pinned in the downward position when not needed (road courses etc). https://farm9.staticflickr.com/8642/...3c54f0ba_b.jpg Couldn't not have the vans waffle grip... https://farm8.staticflickr.com/7561/...3f111886_b.jpg https://farm9.staticflickr.com/8669/...2e8a323f_b.jpg Meanwhile in the paintshop - mold prep for the carbon pieces https://farm8.staticflickr.com/7487/...734b14da_b.jpg https://farm9.staticflickr.com/8572/...bd8081d2_b.jpg https://farm8.staticflickr.com/7539/...d8d403dc_b.jpg https://farm8.staticflickr.com/7513/...b1d8e8c7_b.jpg Hood https://farm9.staticflickr.com/8582/...7125378e_b.jpg https://farm8.staticflickr.com/7560/...fc39b3af_b.jpg |
Some pics of the plugs for the body carbon pieces. These were all machined in wood.
Rockers: https://farm9.staticflickr.com/8682/...32bf65c2_b.jpg https://farm9.staticflickr.com/8570/...85cab04e_b.jpg Fenders: https://farm8.staticflickr.com/7473/...2228fe66_b.jpg https://farm8.staticflickr.com/7515/...cc16ab23_b.jpg https://farm8.staticflickr.com/7466/...6373e00a_b.jpg And the first carbon parts! https://farm8.staticflickr.com/7576/...bfbab9ef_b.jpg Mock up, because we could wait... https://farm8.staticflickr.com/7557/...1aece0b0_b.jpg Shell arrived back from powdercoating: https://farm8.staticflickr.com/7512/...014d5800_b.jpg https://farm8.staticflickr.com/7540/...4cbb7571_b.jpg https://farm8.staticflickr.com/7521/...7ba60804_b.jpg https://farm8.staticflickr.com/7462/...c663a935_b.jpg |
Just wow!! So I apologize if this is an inappropriate question, and please feel free to decline answering, but what does a build of this magnitude cost?....200K?....250K? Im just blown away by the R&D and build quality....hell that E-brake assembly is probably worth more than my '69 Corvette. Anyway, thanks very much for the update....I love seeing these NASA quality builds!
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