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The Skin
Making of the skin was the easiest thing to do after deciding opening/cut lines
for the panel. There is nothing really special about it as it is a part of the
hole body plug. With the glass sitting in its final spot and having valley to
hide wipers and access to wiper pivot points of the regulator the plug for the
panel was completed. One requirement for making a mold was to mask off edges as
they are further needed for the bumper and fenders.
The inner flame
Trunk like few other panels like doors are made up of 2 parts, the outer skin
and inner frame / trim serving couple functions
1. to reinforce the structure
2. to provide uniform weather sealing surface and prevent water and
elements of getting into the storage box
3. provide concealment for mounting steel plate for the hinge and latches
4. make the inner side to look "finished"
Ideally it would had been ideal to have the panel made while having main body
plug and making individual panels, however do to uncertini of how underlying
fenders and cowl would look like. It was opted to make the inner structure at
later time.
Now that the chassis had been made and the actual compartment is finalized with
panels bolted to the chassis, its time to make the inner panel. By filling
the cavity between lower layers of fenders, bumper and cowl and the skin of the
hood it provides a temporary form for making plug or more of a mold rather then
a plug for the panel. Doing it this way we can get an accurate contour of
for the skin following body lines. With the surface established it is possible
to get a very uniform even spacing for rubber seal following edge of the trunk
opening. At same time we can make ribs to reinforce middle of the hood with very
close tolerance and minimizing usage for bonding materials.
Making of the inner plug / mold
After masking off some of the openings and covering bolts, outer rim was filled,
Reasong for doing this first was to establish flush mating of body lines with
rest of the body panels and rubber mating surfaces where then laid up and routed
on the perimeter of the trunk. Bumper area probably should had been made a bit
lower so that has the very minimal spacing between the bumper and the under side
of the skin. Remaining part it was a matter of finding out uniform spacing.
The areas where carved out as needed to make good contact and make it tight
enough.
Wooops.... panel is still in the making, please come back soon for more updates
on it
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