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Re-body My Zed


Falcata

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Next is the bucks for the shape , I made patterns out of Ram board ( its used to protect flooring when doing construction in homes )

Comes in a 50 or 100 foot rolls x 38 inches I believe . excellent for large patterns .

 

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Once the shape is how I like it I make the bucks out of 1/4 inch MDF 

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Here you can see I made the fender cover the top of the light , makes it more sinister looking .

These were tricky to make as the light has a lot of shape .

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 the bucks were made to interlock , this gives it some real strength for sanding and working with the foam

 

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The difference between the ram board and the real wood , made for some challenges for left and right and angle etc 

This pile was not making the cut so to speak ....

 

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I used aluminum flashing to make the shield for the foam around the headlights

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this long silver part is ram board covered with aluminum tape and release wax to prevent it from sticking 

 

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here the fender ends short for a reason , you will see that later

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All prepped and ready for foam

 

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here you can see how the flashing around the headlight prevented it from being buried  

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Well I hope you like it so far there is lots more to come , that's all the time I have for tonight .

And if there are too many pic's just let me know .

Cheers

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Amazing project, look forward to seeing it done last time a saw a 350z get this treatment it came out looking like a poor mans Rolls Royce, and not in a good way :lol:

 

Are there sketches you’re working to or are you winging it 

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8 hours ago, da.murf said:

Amazing level of work there. Well done. Have you an insta or anything to follow?

Hi and thanks for the comments and no not on insta I do have the build on another site .I don't have time to figure out some of the sites are a pain , i tried a few and got so frustrated i gave up .

There's not many pic's because it only lets you load 5 at a time , it wont be long and you will be caught up on here . 

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6 hours ago, Mikey_S said:

this is awesome. Do you have a date in mind for completion?

Hi I am shooting for late this spring , early summer , even if it's done  , but with out some vent covers or inner grill , just to get it out there , I really miss driving the car .

Thanks for your interest 

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4 hours ago, LRF4N said:

Amazing project, look forward to seeing it done last time a saw a 350z get this treatment it came out looking like a poor mans Rolls Royce, and not in a good way :lol:

 

Are there sketches you’re working to or are you winging it 

Hi and thanks  ...........not looking for the poor mans roller look here , it's going to be raw GT3 on the street !!

I did make a few renditions the one for the front has changed , but this is the one for the back , I am no artist .

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Alright some more on the front fenders .

 

Here is a view from inside

 

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Still just roughed in here , this is why I didn't totally finish the nose , in case I wanted to make a change or lucky for me , I had some problems with the foam on the drivers side and it ate the foam below the headlight and I had to redo it.

 

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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 (emblem or Badge ) 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


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First I built some spacers to extend the rear bumper out 3 inches to make room for the pipes to go up 

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8 hours ago, LRF4N said:

Amazing project, look forward to seeing it done last time a saw a 350z get this treatment it came out looking like a poor mans Rolls Royce, and not in a good way :lol:

 

Are there sketches you’re working to or are you winging it 

Do have the link for the poor mans rolls i could do with a chuckle 

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Hi everyone 

The new fuel filler location

More on the back of the car , the quarter panels , I designed the shape of the quarters to be able to accept the use of the factory Gas door .
The yellow masking tape is for me to get a visual of the contour .

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Next is the Exhaust surround , because the back panel below the taillights is curved the exhaust tip needs a surround to make it more of a feature , instead of it just sticking out of a hole .
So i built a plug for that piece and when i make the rear mid panel i will insert it into the panel .
So you can see in the first pic at the outside edges of the tip there is a gap , so the surround will fill that and still maintain the look of it sticking out of the mid panel .
Once the mid panel comes out of the mold the center of the surround will be trimmed out .

 

Ok this blue foam as i mentioned earlier is a bit of a pain , because everything melts it , unfortunate because it machines very well , flexible but firm and the best part is it's $ 8.00 for a 2 foot X 8 foot sheet .

Through networking a Wayne and Don fellow Canadian car builders have introduced me to another source for some Polyurethane foam which is fiberglass etc friendly But , yes there always a But .

I will explain in my next post .

 

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Edited by Falcata
miss one oic
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Back again , and thanks for all the great feedback , I am sure not everyone's going to like it .......

Onto the new polyurethane foam , it great But it only comes in 4 ft X 8 ft sheets with 3 choices of thickness 1 and a half inch or 2 or 3 inch , so the problem is it won't bend ( ok if your building a Lambo everything is basically flat ) 

So I have to find a way to cut it thinner and see if it works . I need pieces minimum 12 inches wide .

I can't afford to farm it out it's $100,00 setup fee and $120.00 per hour , and a large enough Band saw is $3K plus and where do I put ? so that's not going to happen just to cut some foam .

So decided to build my own Foam Saw from scraps from my shop .

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Here is a link to a video of it and version 2.0 lol

 

 

 

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