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And a few shots of my “virgin body” before I got my mitts (and my sawsall) on it. The hood shell:
And a few shots of my “virgin body” before I got my mitts (and my sawsall) on it. The hood shell:
0 2011/05/11 19:03:12
This is the rear body section out of the mold and with most of the mold flashing removed.
This is the rear body section out of the mold and with most of the mold flashing removed.
0 2011/05/11 19:02:26
We couldn't resist and had to "mock up" what the car would look like some day. it was amazing how light these large body panels were.
We couldn't resist and had to "mock up" what the car would look like some day. it was amazing how light these large body panels were.
0 2011/05/11 19:01:08
The entire body weighed in at about 120 lbs. Pretty cool. Of course, it only looked like this until it met my sawsall!! Next we moved the body to the Lucra shop in Oceanside CA where, with their help, my brother and I started bonding the body to the frame. After cutting off all of the mold flashings and cutting the body to slide down over the frame, we were able to begin the bonding process. Because of our limited time (both of us had to be at work on Monday) we worked very long hours and typically locked up well after the Lucra folks had left at night.
The entire body weighed in at about 120 lbs. Pretty cool. Of course, it only looked like this until it met my sawsall!! Next we moved the body to the Lucra shop in Oceanside CA where, with their help, my brother and I started bonding the body to the frame. After cutting off all of the mold flashings and cutting the body to slide down over the frame, we were able to begin the bonding process. Because of our limited time (both of us had to be at work on Monday) we worked very long hours and typically locked up well after the Lucra folks had left at night.
0 2011/05/11 18:58:38
While waiting for the glue and resin to cure, we started putting the suspension and rear end into position. Here, the differential and half shafts have just been installed. the next step is the lateral links, trailing links and toe rods.
While waiting for the glue and resin to cure, we started putting the suspension and rear end into position. Here, the differential and half shafts have just been installed. the next step is the lateral links, trailing links and toe rods.
0 2011/05/11 18:56:39
All sections where the carbon fiber body touched the frame were screwed, glued, and wrapped with carbon fiber lay-up to create a “uni-body” type of construction:
All sections where the carbon fiber body touched the frame were screwed, glued, and wrapped with carbon fiber lay-up to create a “uni-body” type of construction:
0 2011/05/11 18:55:49
Once the rear portion of the body/chassis bonding was completed, everyone participated in the hood mounting ceremony! This was a critical step as it would determine the alignment of the largest panel of the car. The more hands the merrier! So, I did the honors and drilled the ever-so-critical hood hinge mounting holes. Felt good to get the hood on because it actually started looking like a car…sort of anyway
Once the rear portion of the body/chassis bonding was completed, everyone participated in the hood mounting ceremony! This was a critical step as it would determine the alignment of the largest panel of the car. The more hands the merrier! So, I did the honors and drilled the ever-so-critical hood hinge mounting holes. Felt good to get the hood on because it actually started looking like a car…sort of anyway
0 2011/05/11 18:54:36
here it is from the back. it is now basically a unibody as the carbon fiber body and steel frame have been epoxied and fastened together. Only the hood, doors and trunk lid can be removed at this point.
here it is from the back. it is now basically a unibody as the carbon fiber body and steel frame have been epoxied and fastened together. Only the hood, doors and trunk lid can be removed at this point.
0 2011/05/11 18:52:38
After 4 very long days on the left coast, this is the rolling chassis with a body. The wheels are borrowed as PS Engineering had not yet finished making the custom offsets and widths I had sent to them earlier. This is the original shape of the "narrow body". the final version is MUCH wider!
After 4 very long days on the left coast, this is the rolling chassis with a body. The wheels are borrowed as PS Engineering had not yet finished making the custom offsets and widths I had sent to them earlier. This is the original shape of the "narrow body". the final version is MUCH wider!
0 2011/05/11 18:49:51
The car arrived here in early March from my bro’s place where we cut off the fenders, made new ones and bonded them onto my car. This is what it looked like when it arrived. Rougher than i remembered during all of those weekends in CA! Now the real work began...
The car arrived here in early March from my bro’s place where we cut off the fenders, made new ones and bonded them onto my car. This is what it looked like when it arrived. Rougher than i remembered during all of those weekends in CA! Now the real work began...
0 2011/08/15 20:06:26
No matter what angle...she still looked might rough. The order of magnitude of the task was beginning to sink in!
No matter what angle...she still looked might rough. The order of magnitude of the task was beginning to sink in!
0 2011/08/15 20:06:12
Note that all of the black you see on each fender is raw carbon fiber cloth. Not really what most would consider suitable for paint! Also, since we glued the molded fenders on the existing body, the seams had to be completely integrated into the original body and the new shapes had to be contour matched as well. In other words….LOTS of bondo and more carbon fiber! So, I started smearing the bondo and broke out the sanding supplies.
Note that all of the black you see on each fender is raw carbon fiber cloth. Not really what most would consider suitable for paint! Also, since we glued the molded fenders on the existing body, the seams had to be completely integrated into the original body and the new shapes had to be contour matched as well. In other words….LOTS of bondo and more carbon fiber! So, I started smearing the bondo and broke out the sanding supplies.
0 2011/08/15 20:06:12
more bondo, more sanding.....
more bondo, more sanding.....
0 2011/08/15 20:06:12
still more bondo and still even more sanding....throw in a bit of shaping and contouring while you're at it!
still more bondo and still even more sanding....throw in a bit of shaping and contouring while you're at it!
0 2011/08/15 20:05:38
Finally, the left front fender starts to appear out of the bondo dust as I learn how to become a sculptor!!
Finally, the left front fender starts to appear out of the bondo dust as I learn how to become a sculptor!!
0 2011/08/15 20:05:38
Once the fender gets close…a dusting of guide coat is applied and then the fender lightly sanded…that shows you just how bad you did as the low spots magically appear all over the fender. Here is the same fender receiving the guide coat. After some light sanding, i realized i was still an "apprentice" sculptor.
Once the fender gets close…a dusting of guide coat is applied and then the fender lightly sanded…that shows you just how bad you did as the low spots magically appear all over the fender. Here is the same fender receiving the guide coat. After some light sanding, i realized i was still an "apprentice" sculptor.
0 2011/08/15 20:05:38
After lots and lots and lots and lots and lots and lots of sanding…more bondo and lots more sanding, it started to look like a Lister…a REALLY wide Lister that is (it is about 4 inches wider than a late model Corvette Z06!!).
After lots and lots and lots and lots and lots and lots of sanding…more bondo and lots more sanding, it started to look like a Lister…a REALLY wide Lister that is (it is about 4 inches wider than a late model Corvette Z06!!).
0 2011/08/15 20:05:13
Then the body started to appear from the clouds of bondo dust…I am a terrible body dude and sand off 90% of all the bondo I apply…so, I apply a lot of bondo! But...it was actually starting to look good - to my utter surprise.
Then the body started to appear from the clouds of bondo dust…I am a terrible body dude and sand off 90% of all the bondo I apply…so, I apply a lot of bondo! But...it was actually starting to look good - to my utter surprise.
0 2011/08/15 20:05:13
As the fenders come into the right shape… I then add glazing putty to fill scratches and low spots (the reddish brown stuff). While the fenders are getting smoother and better shaped, the putty makes them look even worse…if that is possible. Ok, so it still looks pretty rough…believe it or not…it is getting better. I pretty much worked on it every weekend with a goal of getting it ready for paint by the end of the summer (a goal i did not attain). Well, that is about it for this update.
As the fenders come into the right shape… I then add glazing putty to fill scratches and low spots (the reddish brown stuff). While the fenders are getting smoother and better shaped, the putty makes them look even worse…if that is possible. Ok, so it still looks pretty rough…believe it or not…it is getting better. I pretty much worked on it every weekend with a goal of getting it ready for paint by the end of the summer (a goal i did not attain). Well, that is about it for this update.
0 2011/08/15 20:05:13
Our goal over the past several weekends was to finish the rough shape of the fenders and then cover the body with one final layer of carbon fiber to give it strength. First step was to work on and develop the front fender shape and integrate the large flare into the overall shape of the car. We wanted a wide look without disruption the classic profile of the Lister/Jag style.
Our goal over the past several weekends was to finish the rough shape of the fenders and then cover the body with one final layer of carbon fiber to give it strength. First step was to work on and develop the front fender shape and integrate the large flare into the overall shape of the car. We wanted a wide look without disruption the classic profile of the Lister/Jag style.
0 2011/08/15 19:25:47
Once happy with the shape (after LOTS of sanding and bodywork), we then trimmed a nice single piece of carbon fiber cloth to fit the new fender.
Once happy with the shape (after LOTS of sanding and bodywork), we then trimmed a nice single piece of carbon fiber cloth to fit the new fender.
0 2011/08/15 19:25:47
with a good fit using the cloth, we applied the vinylester resin to permanently laminate the carbon skin to the body. Now it was finally staring to look like all of our work would pay off!
with a good fit using the cloth, we applied the vinylester resin to permanently laminate the carbon skin to the body. Now it was finally staring to look like all of our work would pay off!
0 2011/08/15 19:25:47
We followed the same procedure on the other side as well and had a nice, aggressive look from up front. Now, if you remember, the new rear quarter panels did not fit well and there was a 1 inch gap at the rear of the new flare. So…we “bagged” the fender in preparation for the “pour foam” treatment. We then filled the bag with the liquid foam and allowed it to cure and expand with a little help from our heat source (it was pretty chilly in No Ca when we were doing this).
We followed the same procedure on the other side as well and had a nice, aggressive look from up front. Now, if you remember, the new rear quarter panels did not fit well and there was a 1 inch gap at the rear of the new flare. So…we “bagged” the fender in preparation for the “pour foam” treatment. We then filled the bag with the liquid foam and allowed it to cure and expand with a little help from our heat source (it was pretty chilly in No Ca when we were doing this).
0 2011/08/15 19:24:44
Then we removed the bag and started shaping with a crosscut saw (now we’re on the passenger side) the pour foam shaped nicely and gave us a smooth contour despite the lousy fitment of the rear quarter panels. Here is the quarter panel part way through the shaping process. I know, it looks horrible and rough but...it's the finished product that counts, right?
Then we removed the bag and started shaping with a crosscut saw (now we’re on the passenger side) the pour foam shaped nicely and gave us a smooth contour despite the lousy fitment of the rear quarter panels. Here is the quarter panel part way through the shaping process. I know, it looks horrible and rough but...it's the finished product that counts, right?
0 2011/08/15 19:24:44
With a bit more shaping and sanding, the rear quarter was starting to look good...yes? well, maybe not, but after several very long chilly days, we decided it looked better!
With a bit more shaping and sanding, the rear quarter was starting to look good...yes? well, maybe not, but after several very long chilly days, we decided it looked better!
0 2011/08/15 19:24:44
Still too rough for the carbon fiber skin…the dreaded bondo was applied generously to aid in the final contouring of the quarter panel…followed by a LOT of sanding and mess making. Clearly, all this sanding makes your hair begin to fall out...at least that is my theory and I'm stickin' to it!
Still too rough for the carbon fiber skin…the dreaded bondo was applied generously to aid in the final contouring of the quarter panel…followed by a LOT of sanding and mess making. Clearly, all this sanding makes your hair begin to fall out...at least that is my theory and I'm stickin' to it!
0 2011/08/15 19:23:19
Just like the front, we finally were able to laminate the carbon skin over each of the rear quarterpanels. It felt good to be making progress but, honestly, the car still looked pretty rough.
Just like the front, we finally were able to laminate the carbon skin over each of the rear quarterpanels. It felt good to be making progress but, honestly, the car still looked pretty rough.
0 2011/08/15 19:23:19
A bit of trimming to clean up the fender arches and we now have completed the four corners! Here is a shot when we wrapped up the project for that weekend – its kinda, sorta starting to look like something you might want to drive…almost anyway. Of course, with all of the back slapping and congratulations we gave each other at this stage, we kind of overlooked the massive effort required to turn this into what the car looks like today. It was a fun time but, i am really glad to be done with that part of the project.
A bit of trimming to clean up the fender arches and we now have completed the four corners! Here is a shot when we wrapped up the project for that weekend – its kinda, sorta starting to look like something you might want to drive…almost anyway. Of course, with all of the back slapping and congratulations we gave each other at this stage, we kind of overlooked the massive effort required to turn this into what the car looks like today. It was a fun time but, i am really glad to be done with that part of the project.
0 2011/08/15 19:23:19
1 After getting the body bonded on the chassis and getting the chassis mobile, my bro towed my car up to his place in Oakland CA to work on the body since it is much warmer than here in VA. We made the flares with about 20 lbs of bondo applied to the body and then make molds for new front and rear fenders. Here is the passenger side mold for the front fender flare area:
1 After getting the body bonded on the chassis and getting the chassis mobile, my bro towed my car up to his place in Oakland CA to work on the body since it is much warmer than here in VA. We made the flares with about 20 lbs of bondo applied to the body and then make molds for new front and rear fenders. Here is the passenger side mold for the front fender flare area:
0 2011/07/08 17:55:27
2 This is the process of laying up the widened front fenders. Both and done and curing in the No. CA sunshine (a good thing it was sunny because the hills of Oakland do not get very warm in January!).
2 This is the process of laying up the widened front fenders. Both and done and curing in the No. CA sunshine (a good thing it was sunny because the hills of Oakland do not get very warm in January!).
0 2011/07/08 17:55:27
3 Using the same process, we made molds for the very wide rear quarter panels and then laid up the panels. Here is the "raw" passenger side rear quarter panel in the rough.
3 Using the same process, we made molds for the very wide rear quarter panels and then laid up the panels. Here is the "raw" passenger side rear quarter panel in the rough.
0 2011/07/08 17:55:27
4 Next, we removed all of the bondo and started laying out the cut lines required to maximize tire clearance for the much wider wheels and tires.
4 Next, we removed all of the bondo and started laying out the cut lines required to maximize tire clearance for the much wider wheels and tires.
0 2011/07/08 17:55:05
5 The sawsall made making tire clearance a piece of cake - just didn't really look all that great...
5 The sawsall made making tire clearance a piece of cake - just didn't really look all that great...
0 2011/07/08 17:55:05
6 Next, i took the sawsall to the rear and, in just a few minutes, had massive tire clearance back there as well.
6 Next, i took the sawsall to the rear and, in just a few minutes, had massive tire clearance back there as well.
0 2011/07/08 17:55:05
7 Now the really fun part…fitting the new panels. The fronts fit fine because we made the molds off of my front fenders. There they are after trimming and while we are fitting them to the car. Also, you can see the poorly fitting rear quarter panels – they were made from molds from my bros car which, we now know, is VERY different than my car (yes we are building one for him as well):
7 Now the really fun part…fitting the new panels. The fronts fit fine because we made the molds off of my front fenders. There they are after trimming and while we are fitting them to the car. Also, you can see the poorly fitting rear quarter panels – they were made from molds from my bros car which, we now know, is VERY different than my car (yes we are building one for him as well):
0 2011/07/08 17:54:44
8 The fitment of the rear quarters was simply "outstanding" - not. these required a lot of work to make them fit.
8 The fitment of the rear quarters was simply "outstanding" - not. these required a lot of work to make them fit.
0 2011/07/08 17:54:44
9 Here, little Bro helps with the trimming and shaping of the wheel arch on the driver side rear quarter panel. we both itched for weeks after this project!
9 Here, little Bro helps with the trimming and shaping of the wheel arch on the driver side rear quarter panel. we both itched for weeks after this project!
0 2011/07/08 17:54:44
10 Now the front fenders are epoxied and screwed onto the body. the extra wide shape is starting to become evident and the car is already looking much more agressive.
10 Now the front fenders are epoxied and screwed onto the body. the extra wide shape is starting to become evident and the car is already looking much more agressive.
0 2011/07/08 17:54:20
11 Same process on the rear but the rear just would not cooperate and the fitment was pretty poor. We addressed this later with lots of pour foam and shaping - but that is for another story!
11 Same process on the rear but the rear just would not cooperate and the fitment was pretty poor. We addressed this later with lots of pour foam and shaping - but that is for another story!
0 2011/07/08 17:54:20
12 Now we could admire the very wide backside of the Lister. It is 77 inches wide from fender lip to fender lip!
12 Now we could admire the very wide backside of the Lister. It is 77 inches wide from fender lip to fender lip!
0 2011/07/08 17:54:20