1Greenfoam.jpg
1046 hits | | Posted: 6/30/03
Carving the greenfoam for the body.

2Frame.jpg
712 hits | | Posted: 6/30/03
The drawing for the car was blown up to scale, and a Plexiglas frame was built around it. Note clean...

3Drying_the_epoxy.jpg
745 hits | | Posted: 6/30/03
The foam wedges are epoxied in between the bulkheads on the frame.

4Sculpted_Foam.jpg
838 hits | | Posted: 6/30/03
The foam is sanded and carved down to the desired shape.

5Sculpted_Foam_2.jpg
933 hits | | Posted: 6/30/03
This was accomplished using palm sanders, filecards, sanding blocks and penknives.

6Wood_Glue.jpg
782 hits | | Posted: 6/30/03
Since fiberglass will eat through greenfoam, it is covered with three coats of wood glue to protect ...

7Heat_Guns.jpg
956 hits | | Posted: 6/30/03
The wood glue drying under twin heat guns, set on low. Note distance of guns to avoid melting of the...

8Fiberglass.jpg
988 hits | | Posted: 6/30/03
The fiberglass weave in place. Not shown: Two gelcoats, second fiberglass layer.

9Bondo_work.jpg
958 hits | | Posted: 6/30/03
Fiberglass resin and Bondo are then mixed together and applied liberally over the model. Once a thic...

10Primer.jpg
938 hits | | Posted: 6/30/03
Primer is sprayed on and sanded off to determine where the low spots on the model are. Bondo can the...

11Awaiting_Paint.jpg
1076 hits | | Posted: 6/30/03
After countless man-hours of sanding with progressively finer grits (approx. 50-60 hrs.), the model ...

Osprey_Side_High.jpg
851 hits | 25.27 KB | Posted: 6/30/03
The completed model. More images of the model are available under the "3/D Concept Models" section.