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MC2 Project - Chassis prep


DeLaSoul
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  • 3 weeks later...
  • 4 weeks later...

Okay, photobomb time!

 

Dash mould polish and prep - I changed the profile of the corners at the last minute (hence the filler)

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Joined top and bottom together, filleting wax in the gaps to seal it.....

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Blue carbon fibre cloth and fire retardant resin layup.  The drain pipe is to simulate the roll cage as I wan the dash to almost clip on around it in the car...

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Kevlar tape around "weaker" areas as the build progressed.....

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After several layers of carbon and kevlar, final build up of fibreglass to complete the inside....

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Once removed I found the top surface has a little too much flex/sag so some reinforcement was added....

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Dash out of the mould.  Lightweight, smooth and only needed minimal finishing.  Pretty happy for my first attempt!

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Quick trim around the steering column and the mandatory test fit.....

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Fits around the cage too!

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Turned my attention to the centre console.  Using the original (that was cut to suit the new dash) as a template, it was smoothed and the holes filled in....

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Areas marked out for fuses and switched etc.....

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Smoothed and primed ready for moulding.....

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Went back and did the sunroof mould ready for carbon fibre/resin infusion, first coat of tooling gel coat....

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Fibreglass layup.....

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After 5 layers (need a solid mould) it was time to split the tool from the plug.  Build up took 4 evenings....

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This came apart with no real effort but there were some small defects in the mould that needed to be fixed as you can see in the reflection.....

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Clean up, fix and polish.....

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This is now ready for resin and carbon which I'm not doing as I don't have the equipment so I'm waiting on a friend to do the work.

 

While I wait, move onto the heater ducting.   I needed a cover/duct for the heater matrix so decided to do on in kevlar.  Made a very quick and simple mould tool from scraps of wood and fibre glass filler.....

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So the ducting will go over the matrix and pull air from the cabins original fresh air duct.....

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Build up with kevlar, just because racecar!!!!

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Flash off and trim...

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Separate and trim around the heater hoses....

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Last stage will be to cut and mount the air pipe but I will do that once its all been test fitted to the car.

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And forward onto the instrument binnacle.  I wanted something to hold after market dials and keep them as easy to read as possible.  Start with a dummy layout in card/foam board on the original dashboard mould tool...

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You get the idea.  However, after fitting the dashboard and test fitting the binnacle a number of things were obvious.  

1.  It was bloody ugly!

2. I couldn't read the dials

3. I was really really ugly!

So I started again.  Only lost an evening work but it needs to be right!

 

Mock up made in the car from scraps and tape quickly.  This one allowed me to read all the dials and I hoped could be made sleeker and smoother.  Note I only made half to save time....

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Straight into wood, I'll fine tune as I go.....

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Connect the dots.....

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Move from templates to wood the next day.....

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Prime and look for defects....

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A few areas to work on....Still a work in progress.  

 

Finally, fitted the COP setup, new steering wheel controls and the intake manifold for the throttle bodies!

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Edited by DeLaSoul
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Thanks guys, sorry I was away for so long.  

 

Did a little more last night, decided to recess the dash into the binnacle slightly and setup a panel each side I can use for dials or switches.  Recessing them like this will allow me to flock the binnacle (same as the dash) and put a small carbon panel in the hole that I can change/update as my needs change.  i may even put a set of air vents in to keep me warm/cool.  The small drill marks line up with the mounting points for the display so I know where to drill once it's all done.  More sanding, filling and painting to follow.....

ProShot_20160608_183537.jpg

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