This is a portion of the framework that will hold the fiberglass panel
Foam blocks being added to make passenger side panel
Several weeks later, here is what about 30 small pieces of foam look like.
Another view showing more of the panel so far.
Each piece of foam glued can sometimes take 5 minutes or so to shape to the piece next to it. The fit has to be tight so the panel is strong.
The panel is making it's way towards the catalytic converter.
Another mount point has been added to the car frame, and foam blocks are being glued to a wood block embedded in the foam. The support is needed to hold the foam until the glue dries.
Another view of the foam extending towards the missing driver side smoothing panel. It was missing when I bought the car.
The panel now extends almost to the existing passenger side panel. This is about four weeks into the project.
The start of an inverted wing-shape which covers the underside of the suspension A-arm for good air flow.
A detail view of the 'back side' of the smoothing panel. There are many indentations and components that the panel must fit against when mounted under the car. This is what takes the most time in fitting foam blocks. Similar to a puzzle.
More of the 'wing shape' that covers the suspension A-arm, in a roughed out state.
You can see more of the 'wing shape' here. It creates low drag air flow in this area.
Now you can see the wing shape almost completed. Also notice the wood blocks embedded in the foam at hard-mount points.
Shows the start of fender well support for the panel.
Many separate pieces of foam are used to make variously shaped items. Wood screws hold the foam while glue dries.
Another view of the block gluing process.
A fairly fragile assemblage of foam is taking shape. A fender well support item. After more foam blocks are glued, and shape finalized, glassing begins.
It's starting to take shape. Wood blocks are embedded in the foam for mechanical support.
Another view of the same process.
Hard foam blocks and soft foam is used to hold epoxy and glass to the front tire air deflectors while setting up. The deflector has a sharp radius and glass does adhere well without help.
The almost completed back side of the front air smoothing panel. This is about six weeks work.
Side of the back side of the smoothing panel. Close-up of the wheel well supports.
Here is the 'smooth' side of the panel. Glazing putty has smoothed out the areas where layers of glass overlap. If this were a car body panel, it would take another two months of glazing and sanding to get mirror smooth. Panel weight is 6.5lbs.
This detail shows the oil filter access cover and hole for the Fumoto oil drain valve.
A shot of the now complete wheel well support. This support accomplishes two functions: 1) Mechanical support for the lower panel, and 2) Minimize snow packing into the panel area during winter driving.
And another view.
A close-up showing the tight fit of the foam/fiberglass composite panel.
The start of the driver side smoothing panel. The long wood strips are the foundation to which foam blocks are glued. The stock item was missing when I bought the car.
The first pieces of foam are being glued to the wood support pieces. This panel replaces the missing driver side panel.
All the major pieces are glued now, and time for shaping the back side.
The almost finished back side of the panel.
And the smooth side of the panel. This shows about 4 weeks work.
Rear of car, looking towards gas tank area. Adding mounts for smoothing panel here.
You can see several mounting points in this shot. Also shown, is the thickness of the driver side smoothing panel.
Another view of the mounting points on the right-rear of the car.
This mounting point was added later, after discovering that the panel covering the gas tank needed more support in this area. This shot is facing toward the rear of the car.
This is a shot of the gas tank smoothing panel in progress. You can see how many individual blocks are needed to make this panel. In some respects, this panel is more complicated than the larger engine panel.
Here is the same panel, but smoothed out. You can still see the sanding dust.
Some portions of the panel were sanded too far, and had to be built back up, by either adding spackling, or more foam board.
This is a shot of the finished fuel tank smoothing panel back-side, after being painted in Latex and driven in rainy conditions for a week.
Here is the front side of the same panel. Inspection showed that muffler pipe heat did not affect the panel.
Here are the two matching panels. You can make out the slot for the tail pipe in this shot.
This photo shows the back-side contours of the gas tank smoothing panel.
This photo shows all four panels on the car. You can also see the narrow slits that allow the safety brake cables to protrude through wheel the suspension is at full extension.
Here's a zoom shot showing the rear edge of the engine smoothing panel. So far, the catalytic converter heat has not affected the panel in this area. The white color helps to reflect heat as well.
Now you can see the slot for the brake cable and muffler pipe.
Another shot showing how the panel is radiused by the tunnel to allow for better air flow.
