Building a plug in a shed

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#1

I have been asked to post a few pics/info on a plug I have been working on for the last 6 months, it is of a Porsche 917`esque replica that I hope to get road legal. So I will begin with the first step, bought 14 sheets of ply and managed to get a decent 3 view drawing from the net, using this, I just scaled it up and got cutting

looks a bit rough but this was how it all started!! I then shuttered between all the formers using ply stuck with P38 filler (it dries quickly)

Over the ply I used Easy sand filler to get the shape somewhere handy (I used over 70 5kg pots in all!!) Then after much sanding/priming/flatting/polishing it was time to get the wax out and make some Alloy fences for the mould joins

The above shows the rear section fences going on. I then started work on the front, doing recesses for the screen/headlight covers/doors etc, long drawn out process and then spent a lot of time getting it all how I wanted, this brings me up to date more or less and shows where it was 2 weeks ago

I have now sprayed the front section with 2K black (to show any bumps etc) and flatted/polished it up ready for fences/wax and gell.
There are a host of photos on my flickr site that gives a better picture of how I have gone about it here http://www.flickr.com/photos/47153142@N03/sets/72157623861979360/
All of this work was done the “old fashioned way”!! no computers or CAD
regards Chris

#2

Wow, that looks amazing! You’re quite a sculptor.

#3

Awsome! What great skills you have. Love to see a finish product when you get to that stage.

#4

That’s amazing Chris. I can’t beleive the accuracy on a hand built plug!

#5

Good god… :eek: I’m not worthy, I’m not worthy…

What’s the composition of the molds? CSM weight, how many layers, gel coat, and resins used?

#6

your thread title is building a plug in a shed.we built this race car plug in a carport in the middle of winter.we put up tarps to keep some heat in.the plug is for the new west wx10 d sports racer.me and 2 other guys spent months shaping it.its mostly pink insulation foam and body filler.30 gallons of body filler to be exact.i just wanted to post these here being i have done a similar project.i know the effort it takes to get a full body built with molds.the second pic is the finished car at the 09 run offs in carbon.

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#7

Thanks for your comments guys, it has been very rewarding, cant wait to get some steel tube and get cutting and welding! Re the mould info, I just used tooling gell (2 coats) a layer of 300CSM then built it up with 450, plenty of layers (cant remember how many mind!)
I guess its a legacy of building lots of model aeroplanes when younger from drawings helped when doing this. Re the accuracy, I am sure that anyone who has built a plug before will be able to tell you where the 2 sides are not exact or any other imperfections are!! I know of one such area on my plug (this would not happen with a CNCd mould but I feel adds a bit of character to it!!!:)) and having looked at various original cars can say that they are not that perfect! But I have tried as best I can!
For the production body I will lay up using CSM and polyester for a knock about body to use when making the spaceframe chassis and various other internal panel moulds etc with a view to doing a lightweight fibreglass cloth and epoxy body for the final body using wet lay-up, I have been toying with Infusion after stumbling over this site but feel that with my lack of knowledge and the multi-part moulds Infusion could be a very expensive failure, esp if I use carbon but we`ll see, may try infusion with glass first, see how it turns out.

#8

Chris it might be worth you putting a link to your flickr stream as you have a lot more photos on there! you are certainly putting in the work with all the different moulds and the shut line recesses for the lights and doors etc that you have done

#9

Nice work! The Michaelangelo of filler!

#10

Great work! I look forward to pics of the progress.

#11

Very nice! I’ve always wanted to try something like that but it’s obviously a lot of work and dedication to see it through.

#12

http://www.flickr.com/photos/47153142@N03/

#13

wow i am blown away… looking at that makes me realize how bad i suck at bodywork.

i could never build a plug from scratch and have it turn out that smooth.

i am half tempted to give my “plug” to a body shop to have them true it / prime before i continue on with the rest lol

#14

Thats Amazing thanks for the pics. to think you started with a pic off the net fantastic job

#15

How did you cut out the windows and things?

#16

Window recesses were scribed on the buck and then 4mm wax was used to the shape in the master mould. Front hatch and light covers were cut in with a grinderette with cutting disc, then the fine work was done with sandpaper/block and anything else that cuts filler/wood that came to hand.

#17

Very good job

#18

I already gave you some compliments, but I just looked at your Flikr page and your work is rediculously amazing! Are you building the chassis too?

Please keep this thread updated!

#19

Amazing quality work there. Yep looking at that my bodywork skills need some brushing up on to be sure.

How many man hours are into this finished plug?

#20

it is great.