Falcata

[Falcata]

More exhaust , the tip is 3/16 ths aluminum plate and the tubing is 2 1/2 with hand formed ovals , it's all mounted with rubber isolation stand offs

[Falcata]

So in order to get the exhaust up into the middle of the back I built some rear bumper Extensions like the front , they are 3 inches and bolt directly to the car and the factory bumper .

[Falcata]

Ok lets go to the back of the car for a change of pace .
Falcata is the name of the car , I named it after a Spanish Sword It was considered a very deadly weapon .
So the logo for the car is two sword ends put together , I designed the exhaust tip from this idea , the first pic is a little solder holding a Falcata and here is the signature exhaust .
It's 24 inches long and 4 inches tall

[Falcata]

More Front end stuff ....
Ok remember I said I would explain why the back of the fender didn't go to the door , ( in the first pic ) well it's because of the door hinge pivot point .
In order to have the body wider and not have the door hit the fender when the door opens I came up with a plan that the wide part of the door goes into a pocket at the back of the fender .
If I was building just one car for my self I would have extended the door hinges , But the average guy probably can't cut the door and the hinges and weld spacers to them . so this way the door doesn't even have to come off the car.
So now it will look like the door goes into the fender with a vent along the edge of the door . ( I will take a video in the next couple of days )

[Falcata]

More fender stuff .
I am by no means a expert at this so if you have any advice to help things go along smoother or fast , please let me know .
Some shaping

[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 .

[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 ,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 ....

[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]

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

[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]

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]

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 , 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]

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 .