Falcata

[Don Senior Member Find all posts View Profile Close Don]

Looking great Phil.

[dobie44 Active Users Find all posts View Profile Close dobie44]

That foam really seams to be working for you Phil. Your kinda doing what I did on my build replacing all the foam that is attacked by the polyester resin with the urathanian foam. The results are looking really good!!
Wayne

[Falcata Senior Member Find all posts View Profile Close Falcata]

Thanks for the kind words , Wayne and Don .
Yes the new foam is working well , I am now a nurse at home , as my wife had a knee replacement on Friday , I will be making a few parts at the home shop for the car , I need to machine a small mold to hold the front signals .
They are small amber LED's .

I will catch you guys up from my last post to here.

and along the way was working on the attachment points , originally I was going to use the factory hatch hinges to hold the rear clam shell down but found it really difficult to access the bolts with the top on .
So if you are racing the clock with bonding compound to attach the roof this might prove to be a problem .
So I came up with a new idea to bolt the rear down using the rear strut mounting location , now there will be a foe vent to hide the fasteners .
I try to use the lasers and grids to insure things are staying symmetrical , this car has so much shape its like working on an egg all the time !!!

So in case there is any confusion with this , there are two parts here the lower one is like the hatch replacement , which seals the back of the car and the top part , which will be the outer cover ( body ).
These two parts will be bonded together before they go on the car.
Then the combined part will be bonded to the roof and bolted here where you see bolts , then a small flat piece will be bonded over to hide the bolts .


The part you see with the bolts below will be fiberglassed from the other side once it's been removed to copy the parts for production.
Because the under side is already finished in gelcoat and I can't get at it until then .

[Falcata Senior Member Find all posts View Profile Close Falcata]

More on the rear anchor points , which will become fake vents .



Here you see the some thin fiberglass , I made a few sheets of it in different thicknesses , of coarse the thinner the more flexible . I find it very handy , you can cut it with tin snips or scissors on the really thin stuff .
The black line is where the foam will end and once the rear clam shell is made that will be cut out a 1/4 of an inch smaller to access the bolt to attach part , and a revel for the cover to be bonded onto .

Next is to foam and shape .

[Falcata Senior Member Find all posts View Profile Close Falcata]

Rear anchor points / foe vents .
roughed in , this will give you an idea what it will look like .
should blend in with the rest of the craziness ....

[Falcata Senior Member Find all posts View Profile Close Falcata]

Hi guys & gals
Been a while , must be getting old almost forgot how to post stuff on here lol .
I have missed some time from the car ( obliviously ) you know the usual stuff in the forest on an Island , power outages from wind storms and freak snow storms , life etc .
So I have been plugging away at the rear deck lid fake vents and prepping the roof scoop mounting . the roof will have a small foam frame that will be part of the roof to position and fasten the scoop .



The factory roof cap tapers into the vent





laying out the foam to make the frame for the roof mount



I hung the wing from the overhead door rails to get an idea if I was going to like it , I like the ends but they will be too difficult to make .
So the end would get cut off and there will be plates on the ends .

[Falcata Senior Member Find all posts View Profile Close Falcata]

Hi I finally got my turn signals , they are really cool , they have low beam ( DLR ) day time lights , high beam DLR and Amber sequential signals , I ordered a few sets and the shipping company lost them !!!!

Had to order again .......

So I will be working on there spot in the front Dam , this should be a right pain to make also ... but worth the effort .

They are aftermarket up grade for the new Honda Civic Type R



Would be nice to find a wrecked Civic Type R and make a mold of the light housings .......I looked at buying an aftermarket on to copy .................$2600 USD plus shipping ...... Not going to happen .

[Falcata Senior Member Find all posts View Profile Close Falcata]

Hi

I am back with an update , I have been working on a few things .

The roof scoop frame that will be the mounting point and will be part of the roof .

This was a tricky piece to make ......like everything else was easy lol .



The part that covers the top of the windscreen will be made with the whole roof and cut off after , so the roof scoop frame will need to be cut also , and the nose of the frame will be attached to the part that goes over the glass , for easy removal for windscreen replacement .

[Falcata Senior Member Find all posts View Profile Close Falcata]

Hi Everyone

Been busy it seems to me , I know I built a mock up trunk to build the trunk and make it function off the car but it's hard to know if it looks right off the car , so I have been doing some mock up stuff .

My original plan was to make each louver in one piece , it is too difficult , so this is what I am thinking .




So you have to have some imagination here to see this all body worked

[Falcata Senior Member Find all posts View Profile Close Falcata]

Well I didn't like the bars going down the middle , and it would be a nightmare to sand .

So I came up with an idea to make my original idea work , of course I had to make all new pieces ....

It's getting there , the plan is to lay up a few thin layers of fiberglass mat and then cut the part where the trunk lid opens . then I can finish the trunk lid off the car with the mock up

rear body part I made for that purpose , I know it's all a bit confusing .

So hang in there !!!





This is how many times I tried different ratios of height and length to get what I thought was right , just like CAD ( computer assisted drawing ) only WAD wood assisted drawing

LOL LOL

[Falcata Senior Member Find all posts View Profile Close Falcata]

Continuing on







Just the top to sort out and then filler and fiberglass , Might try making some Rondo

[Kent50 Active Users Find all posts View Profile Close Kent50]

Beautiful work!

[AjzRide Active Users Find all posts View Profile Close AjzRide]

Next time you get it outside I would love if you could get some wider range shots. Having a little trouble picturing how it goes together.

[Falcata Senior Member Find all posts View Profile Close Falcata]

Next time you get it outside I would love if you could get some wider range shots. Having a little trouble picturing how it goes together.

Hi AjzRide
Would love to get it outside , but at the moment the car has no suspension in it and the car is sitting at ride height and all level . ( couldn't get it in the right position with the suspension and the wooden wheels )
So it won't be going outside until it's nearly finished

[Falcata Senior Member Find all posts View Profile Close Falcata]

So Porsche had the Whale tail , the Falcata has the Lobster tail lol

Everyone seems to really like it .

Fist couple of pics finishing the foam at the top and filling in the gaps .

I tried this for the first time yesterday , Discovered this from Wayne it's known as Rondo a mixture of Fiberglass Resin and body filler Bondo , blend and you get Rondo .

It helps to seal the foam for easier fairing ,sanding , filling and fiber glassing .

Seemed to go well , will know later today .





Having trouble with posting pics , I got a new phone with a 64 mg camera , I resized the pics but its not working this time around .