American Ethos (2025) Electrathon America Racer

[Functional Artist]

I'ma thinkin' that a bit of water

"Misted" on the underside, of this Hardboard
...should help "soften" 'er up

Then, add a bit of pressure &/or "coercion" to get 'em, ta curve nicely

Everything seemed ta be goin' pretty good

I got the center strip ta curve nicely around the tire
...& "tucked" under a frame rail
...plus ~1/2" of "padding" to help ensure tire clearance
But,
While workin' ta curve the left strip
...& "tuck" under a frame rail
...it "SNAPPED" (that was NOT part of the plan)

OH...DARN

Well, HECK
...while I'ma at it, lemme see what I can do with, the other strip

Hmmm...that's not too bad

But, when I went ta curve 'er down a bit more
..."SNAP"...again

Well...I guess
...back ta the drawin' board

 

[Whitetrashrocker]

Less mist, more soak.

Ive said for a while now;
Anything worth doing right is worth doing twice.

 

[Functional Artist]

Less mist, more soak.

Ive said for a while now;
Anything worth doing right is worth doing twice.

Hey WTR,

Sometimes...even more times

Here is (what's left of) the hardboard floorboard
...but, we can still use it as a "template' ta make...more

Here is the front wheel with the 1/2" "spacer" pad (2 pieces of 1/4" foam rubber taped in place)

I wasa lookin' on FB Marketplace
...& found an ad for (2) 4' x 4' pieces of Formica (countertop material)

They were brown & scuffed
...but, couldn't beat "both for $5.00"

Plan B
Used the Hardboard "template" ta "mark 'em up"
...& the Table saw ta "cut 'em up"

Yup, I made (2) in case I mess (1) of 'em up

Test fit"
...& yup, they "B" more flexible

This is how I'ma formin' the "Nose panel" & footwell

Side(er) view

* Initial "mock ups" went pretty well (no breakin')
...so, I went ahead & "doubled 'em up"

Seemed like it would make the structure stronger
...& help it to "hold its shape" better...too

 

[Functional Artist]

Weather man lied...again

I got a lot of the floorboard "mocked up" & glued
...& then, went on a tow...while everything...dried
&
While I wasa gone...we got a "pop up" rain shower

Even, "soaked" my camera
..."see" the vapor "blur" in the middle of the pic (w/Ducky)?

Before leaving, I made up a CAD "fender sidewall template"
...but, it got wet/destroyed in the "deluge"

Luckily...I had used it to "mark" a piece of wood...before leaving

After the fact, I found a use for this old plastic kids pool (with a crack in the bottom...so, it don't hold water)
..."rain blocker"

Wooden, fender "sidewall" insert

 

[Functional Artist]

I "finagled" (technical term) the wooden fender side wall insert "in place" (in-between the wheel & the floorboard)
...but, it "left" some "gaps"

There is a pretty good sized "gap" in the rear

...& a bit of a smaller "gap" in the front
...but, still "gappy"

So, I made some "notes-n-notations"
...& then, made up another one (or 2)

* Also, notice, I made (V2) out of 1/2" MDF (Multi Dimensional Fiberboard)
...which gives us a nice-n-wide gluing surface
...& some bulk/thickness, for "rounding" the edge

Yup, (V2) fits much better
...nice-n-tight

Another view

 

[Denny]

Now glass it all together to make a plug to make a mold.

 

[Functional Artist]

Now glass it all together to make a plug to make a mold.

Hey Denny,

I'ma thinkin' "this" will be the mold

Just gotta "stiffen 'er up"
...so, I can "take 'er off" the chassis

So, I used spray foam (ta help 'er hold its shape)
...& "lock" everything together
...& "firm" the whole unit up a bit
&/also,
I installed a tube
...& inflated the front tire

* Pic "caught Ducky sleepin' again
...& still has the "vapor" spot

 

[Functional Artist]

Got the front fender/floorboard "form or mold" off the chassis

Spray foam helped 'er to "keep the shape"

Body work...Brought to you by Bondo (body filler)

I used the bottom 1/2 of a plastic "bolt bag" (re-purposing)
...with the corner "cut off"
...as a (like for decorating cakes...I don't remember...so insert name here)
...to "squeeze out" the body filler
...into the "corner"

I got 'er all "roughed in"

* I used a 14mm deep well socket to help "establish" the "inner curve"

Across the front...too

 

[Denny]

You’re making a mess now!

 

[Whitetrashrocker]

You’re making a mess now!

Just wait till he starts sanding...

 

[Functional Artist]

You’re making a mess now!

Hey Denny,
Ya gotta bread some eggs ta make a...(you know)

While that "mess" wasa hardin' up
...I added a piece of cardboard as a bottom (as the mold was kinda "rock-ity")
...& it should make 'er stiffer & stronger too

Got another can of spray foam (as the last can was "leftovers" from makin' the monocoque "mold" for Diamonite)
...ta fill 'er in

* Spray Foam Tip:
The Window & Door "type" doesn't expand as "aggressive"
...or exert as much pressure
...on the "area" being foamed

Got 'er mostly filled in
...& do ya see what I see?

This here "drip" looks like a 'wittle Ducky

 

[Denny]

Hey Denny,
Ya gotta bread some eggs ta make a...(you know)

While that "mess" wasa hardin' up
...I added a piece of cardboard as a bottom (as the mold was kinda "rock-ity")
...& it should make 'er stiffer & stronger too
View attachment 155235
Got another can of spray foam (as the last can was "leftovers" from makin' the monocoque "mold" for Diamonite)
...ta fill 'er in

* Spray Foam Tip:
The Window & Door "type" doesn't expand as "aggressive"
...or exert as much pressure
...on the "area" being foamed
View attachment 155231
Got 'er mostly filled in
...& do ya see what I see?
View attachment 155236
This here "drip" looks like a 'wittle Ducky
View attachment 155237

I mostly see how momma is going to kick your azz for screwing up her picnic table!

 

[Functional Artist]

I mostly see how momma is going to kick your azz for screwing up her picnic table!

Hey Denny,

Thats the old picnic table
...& I already got in trouble for that

Ducky says "The Bondo is good-n-hardened up
...& the Spray Foam is good-n-set...too"

I'ma usin' this knife ta "cut away" some of the excess (ta save some sandin' time)

Yes, this excess
Kinda "whittles" like wood

Usin' that 14mm deep well socket helped us make some nice "fillets"

Then, I used a router w/a 1/4" round over bit ta
..."round off" the edges, of the fender (ta save some sandin' time)

Kinda like this

 

[Functional Artist]

For smoothin' here are my Sanding Weapons (or aids)

Usin' some 40 grit "rock paper" (as ya can't really call 'er sandpaper 'cause its really rough)
...& some 80 grit "smaller rock paper" (not quite as rough)

We can use the sticky-ness on the backside for attachin' ta tools

The sticky-ness is good for makin' (2) sided "sanders" too

After removin' some of the excess
...I used a "round sander" ta do some "inner" roundin"

Still sandin & roundin'
...& makin' progress/gettin' closer

&
Yup, me & Ducky are usin' a koolin' &/or exhaust fan whilest a sandin' & roundin'

 

[Functional Artist]

Ducky says (while takin' a break from watchin' a foam "head lookin' thing" expandin' from the inside of a foam formation)

"What about curvin' the transition
...from the floorboard upwards to the "front panel"?

Don't cha needs ta do that?

Um...yea...maybe...I guess

So, last minute
...addition
...or script change
...&/or plot twist

So, I added a piece
...& then, Ducky says (while still watchin' the foam "head" raisin' outta the foam Volcano)
"Wow! ...that is quite the transition"

 

[Denny]

As long as you already got into trouble with mama I’m good with that!

 

[Functional Artist]

I got the floorboard mold all rounded & sanded pretty smoothed
...then, sealed 'er up w/Satan Black spray paint

* Remember "this" is the mold
...so, we mainly need 'er to be all smooth & roundy (technical term)
...& any imperfections "seen" will be on the underside, of the fiber glassed piece

View from the rear

View from the front

Close up view

 

[Denny]

I really don’t see how it’s a mold. It looks like a plug for a mold.

 

[Functional Artist]

I really don’t see how it’s a mold. It looks like a plug for a mold.

Hey Denny,

Well...I did some measurin'
...& note makin'
...& then, applied those "specs" to some 1708 Fiberglass cloth

* Notice I'ma wearin' some PPG (Personal Protective Gear)

I used (1) of the wooden 1/2 circles I made up as "rough" templates
...ta make the fender "side panel" pieces

Ducky says we B ready ta do this

Mold Separation Wax

Instructions say to apply several (3 - 5) coats

At the last minute I noticed that those "holes" needed covered
...so, we will produce a nice-n-smooth surface
...& we'll re-establish those holes...later

A couple of "strips" of box tape did the trick

First coat of mold wax

First coat of mold wax
...buffed off

Second coat of mold wax
...& buffed off

Third coat of mold wax
...& buffed off

 

[Functional Artist]

From my YouTube University edumication

I learned that some folks also use a product called PVA (Polyvinyl Alcohol)
...which is basically some kinda plastic dissolved in alcohol
...& when spread over "something" it creates a thin "plastic barrier"

* This product is a mold release "agent" on its own
...but, we are basically using it as a "secondary" release "layer"

* This product is "water based"
...so, it can be easily removed/washed off with plain 'ol water

* Notice at the end of step 5 it says "enjoy your success"

I just brushed 'er on with a foam brush (recommended in the videos)
...& spreads kinda like oil-based paint

Close up view of what coated vs. un-coated looks like

All Ready to Rock