Falcata

[Falcata]

Scoop , first one out !!!! it turned out pretty well had some issues , it's winter , keeping everything at optimum temps can be a challenge

[Falcata]

Scoop trimmed and test fit .

[Falcata]

Headlights are Mazda 3 the aftermarket Angel Eyes Projectors
Had to make pots for them to bolt into , I tried to make the Plug for pots with two part foam , that didn't work very well , so I made them out of wood , as usual that was a pain in the butt , a ton of work to make one part .

[Don]

Looking nice Folcata;

Where on Vancouver Island are you? I am in Victoria and just about done my 308 replica and will be on to my Countach this year.

Keep the pics coming
Don

[Falcata]

Hi Don
I am also in Victoria , I will check on your build for sure .

[Falcata]

More on the front end , The first thing I did in glass was a copy of the bottom of the hood , mostly to test my set up and make a part that didn't really matter , I had some old resin from a boat job I had done a couple of years previously , and was sure it had been below the recommended temp in my back shed , as expected it had lumps etc. so it didn't turnout very nice . Headlight buckets and the front bumper cover support , the first pic is pulling the PVA off the part .

[Falcata]

More front end , i decided to build a one piece structure to support the headlights and the front fenders and the bumper cover and the splitter , with fixtures for the air ducts .

[Falcata]

So the center red piece , the headlight buckets and the black bumper ( factory foam ) part will be glassed as one part . I got excited to see some shape in the car and two part foamed the nose before this happened , which is alright because I will probably have to add tabs or put fasteners in it anyway .
As you can see I kept the factory tow hook also .

[Falcata]

More front end stuff , so here you can see that the front support piece in the second pic and the second last pic without the headlights in , red and the grey parts will become the one , I will have a two piece mold so i can release it , the seam will be the top front edge just below the headlights .
So when you get your new body , you remove the factory bumper cover , fenders , headlights and hood .
Install the front bumper spacers ( 2 inches ) and install this under the nose part first .

[Falcata]

More front end ....Fun with foam !!! I built a system to measure so i could do my best to keep it the same on both sides , it's like trying to measure an egg !!! the foam cuts and sands like butter , it's very easy to go too far .

[Falcata]

Here is a sketch of what it's going to look like . more updates a soon as i can .

[Kent50]

I am really enjoying this build thread. You do amazing work and I cannot wait to see the end result. Thanks for posting!

[Falcata]

More front end stuff ,I made fiberglass copies of the stock front fenders to use as the base for the new fenders , because I want to use as much of the factory mounting points .
Also made a glass copy or the wheel arch , save figuring all that out as well , I used small diameter steel round bar to set my top edge and flat bar to mount it to the top of the existing fender .
Then I made templates out of Ram board , (it's like thin cardboard ) then transferred them to 1/4 inch MDF bucks which get glued on , as you can see the outer wheel arch is set out further on blocks .
It looks easy in the Coles notes version here , there is weeks and weeks of work in these fenders , and more to go .......................and I wondered why nobody had done this before ....

[Falcata]

More front end stuff
As you can see there is a big difference between how the Ram Board and the MDF sit , lots of do overs along the way , but it has to be strong enough to sand and glass over with out it warping .
I want this car to be evil looking , a seriously mean GT3 race car for the street .

[Falcata]

More front end stuff
Next is to prep for the two part foam on the fenders , I made a border around the headlights with some aluminum flashing , the first time with the foam I was too excited about seeing some shape in the car after months of building the rear inner and outer hatch covers , i buried the lights in foam , it was a total pain in the butt to dig them out without scratching the lights . In the last picture I will explain in the next post why the fender does't go to the door , that little pocket at the top is to hold the foam .
Still lots of shaping to do .