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Now that the curiosity of building a full size body had bitten us in the
rear end and having a model and ideal how to improve on we had started
purchasing some foam. We had decided that rather then purchasing a huge block of
foam it would be better to bug 2" thick sheets and have them glued together. We
had started with the front bumper and wanting the plug to be the lightest. Each
slice was cut over the size so that after all the slices are glued all that
would had been needed was to sand the foam down rather than having it building
it up with either more foam or fillers which would make it heavier. The front
came together rather quickly, mid section and the rear as result of it had a bit
of delay due to sourcing of OEM glass for windshield and door glass as we wanted
to use OEM glass rather then having it custom made to fit the needs. Once the
glass was sourced rest of the general foam construction was completed.
As plug was constructed in space that was used for other purposes it was build
in 3 sections: 1. front which included the door section 2. rear including B
pillar, firewall and rest of the rear and 3. upper section which included
windshield surround and roof panel. The sections where build using wood formers
having 4 main beams running from front to back and screwed together in the rear
firewall area to be able to split the plug in half. Thin sheets of MDF where
used to stabalize the 4 runners from moving and diagonal connectors triangulating
everything to make the hole assembly very dimensionally ridgit when moving. Some
of the construction principles can be seen in the plug gallery. Heavier boards
extending to the sides served as fastening points for the foam with front having
heavier card stock embedded between foam layers in the early stages of
construction proved to be adventogous then fastening the front bumper /
hood section to the wooden frame lattice.
.............. more to come
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