Mirroring, Part Three

(20 days until the 2012 WHPSC)

Filling in the spaces with strips of wood so we don't use another 15 gallons of Bondo...

... sawdust mixed with resin (bulk filler)...

... bondo...

... and ceramic balloons and high fiber.

After knocking down the high spots with a sander, this will get a slick coat of Bondo

Buzzing the Bondo with a gear drive

He makes this look easy...

... the same way Eric Clapton makes playing the guitar look easy

Filling in a couple more areas

Starting to look like the other side

From the rear

Mirroring, Part Two

(21 days until the 2012 WHPSC)

Getting ready to mirror the other side

Stations in place

Applying Bondo between gap in body and each station

Dad is holding a station while Doug applies Bondo

Bondo cures VERY quickly in this heat, so the stations are ready to be removed in minutes

Dad checking with a horizontal guide

Stretching tape

Stretching more tape

And here's what it will look like!

From the back

From the front

Angled front shot

Angled side shot

Closeup showing the ribs molded by the stations

Back to the subframe... A little further along here - finally ready to spin it up!

Mirroring, Part One

(22 days until the 2012 WHPSC)

Here's where the mirroring stations will go

And here are the mirroring stations

Closeup of mirroring stations, which are about to get filled with Bondo

After filling with Bondo, here's one station flipped to the other side

Remaining stations

More metal fab... mocked up a derailleur hanger...

Closeup of the hanger

High-Build Polyester Primer

(23 days until the 2012 WHPSC)

Shot high-build polyester primer on the first side of the streamliner tooling plug.

From the front

From the back

Closeup of back

Closeup of front

Closeup of canopy mockup

Closeup of canopy looking forward

More metal fab... Welding another pinch clamp (notice the sparks where the work is grounding to the table)

Another shot of me welding

Closeup of the welder

Back at the "ranch"... getting ready to mirror the finished side to the other side

Here are where mirroring stations will be placed