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Old 05-26-2017, 09:40 PM
longyard longyard is offline
MetalShaper of the Month September 2013
 
Join Date: May 2012
Location: Winston-Salem, NC
Posts: 1,083
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Quote:
Originally Posted by zekeymonkey View Post
Very cool project. How did you go about making the nose section?
The nose is made up of the first three laser cut stations (8 inches depth). I epoxied 3/4" red oak to the back of the first station and then made kerf cuts in the oak which I filled with a slurry of epoxy and wood powder. While still went, I placed blocks under the ends of this panel and using an automobile jack pressed down the center while under my work bench. This gave it the required curve. I then added other pieces of oak and foam. The headlight extensions were made from turned billets of plywood, and faced with .090 aluminum. The whole thing was then covered in fiberglass reinforced plywood, and then fine tuned by my friend Joe Schiavone.

I plan on making a Flexible Shape Pattern of the whole nose, and then dividing that up into small sections. I'll use my Mechammer to shape each piece to fit the FSP. Final finishing will be done on the nose buck, including the rounding over of the "mouth". The "mouth" must be turned over an inner tubular "mouth" which is part of the Superleggera system.

I painted the nose glass grey so the first layer of FSP tape would peel off more easily.

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Bill Longyard
Winston-Salem, NC
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