Diamonite Electrathon America Racer

[Functional Artist]

Notice how cuttin' is so much easier, when workin' with smaller pieces

Ta make the rear "deck" I had ta cut/trim out, around where the seat goes

With the "sponces" in place
...the rear "deck" panel
...& seat installed
...it kinda looks like this

Another view

Nice-n-tight "fit"

 

[Functional Artist]

Monocoque "tub"

Modified monocoque "plug" (in the rough)

 

[Whitetrashrocker]

The woman let you inside?

Coming along buddy.

 

[Functional Artist]

The woman let you inside?

Coming along buddy.

She was away, for the afternoon

&/or/but/also

The "house rules" are
...no drillin'
...or cuttin'
...or grindin'
...or sandin'
...&/or weldin' in the house
&
I ain't didn' none of those things ...yet
...so, I'm"good"...for now

 

[Functional Artist]

Rough drawin' of the cockpit area (w/modification/concepts)

Simply flipped over...for better context/understandin' ta make the "plug"

Drawin's w/measurements of the various inner "ribs"

Top view of "plug" (in the rough)

Another view

 

[Denny]

He, he, he. He said cock pit.

 

[Functional Artist]

Notice "we" (the "plug" & tools) are outside

For some corner routin'

...& some roundin'/shapin'

 

[Functional Artist]

To use as "fillet" material, I cut a 45* angle. off of a piece of 1/2" MDF
...& then, cut the 45* piece off
...so, I had some 1/2" x 1/2" x 1/2" triangular type material ta work with

...& used some ta "fill in" & "round off" this area

Another view

 

[Functional Artist]

Usin' a 80 grit disc, on a grinder, for more roundin' & shapin'

Closer upper view

Another view

Then "moved on" to a palm sander

...also w/80 grit

Another "smoother sanded" view

 

[Functional Artist]

Been workin' on the "ends" (nose & tail)

Addin' some "guide lines"

Front/Nose "guide lines"

Tunnel outlet "parts" (flange & beginning of the tunnel)

Tunnel outlet flange assembly

Tunnel outlet flange(s) "mocked up"

*FYI: this "mock up" is just for illustration purposes
...as they are currently inverted (as in upside down)

 

[Functional Artist]

Cut a bunch more "flange" material(s)

Ta help "round off" the inside corners, like these

Notice, them "fillets"
...are kinda like floor trim
...around the perimeter

Helping ta "round the corner"
...& "sealing off" the (horizontal panel to vertical panel) junction

* Except...your lookin' at the top
...NOT the bottom/floor

 

[Whitetrashrocker]

Your turning into quite the wood elf.
Nice work.

 

[Functional Artist]

Your turning into quite the wood elf.
Nice work.

Hey WTR,
...thanks, my friend

 

[Functional Artist]

Someone in the back says:
"Seems to be getting...kind of complicated/"boxed in"...back there
...how you going to get the "piece" out of the mold?"

Well, I'ma glad you asked

I designed the rear section, of the mold, to be removable

Jualla

 

[Functional Artist]

Rear section of the mold
...with tunnel flanges

Separated from the "main" mold
...still "technically" inverted

Un-inverted
...or maybe verted

* Notice the nice ~2" "lip"
...that we should "get"
...along the bottom
&
The ~2" "wrap around" flanges
...that we should "get"
...along the sides
&
How they should
1.) help "stiffen" the "tail" of this chassis/monocoque
2.) produce nice "connecting flanges" for mounting the "outer" body (side & floor) panels

Close up of some of the "trim" work or "fillets"
...that are "bridging" the horizontal to vertical transitions

An even closer
...upper closer looker

 

[Functional Artist]

Been workin' on the "nose section" of the mold

* Notice the wrap-around side flanges

** For reference, it's currently "facing" nose down

Side view

* Notice the markins' for the frontal air intake(s)?

 

[Functional Artist]

Frontal air intake (parts/sections)

Frontal air intake w/built-in side flanges

Frontal air intake installed kinda looks like this

Another view of the frontal air intake w/top & bottom flanges

One more view, of the frontal air intake, for mor better reference

 

[Functional Artist]

Removable "lid" (on right)
...for the "nose" section
...w/flanges

"Nose" section w/lid installed

Close up view of
...the "lid" flange
...to ~1" "face" (of the "nose")
...to air intake flange

In-verted "nose" section

Verted (technical term) "nose" section

 

[Functional Artist]

Happy 420 you'all

Back ta workin' on the "main" section(s)

Got the rest of the perimeter flanges installed
...& all associated fillets

Another view

Added some strategically placed holes

Another view (from the bottom side & without the cockpit "hump")
*Notice the "underbelly" access port?

 

[Functional Artist]

Also, been doin' some bodywork

Applied some wood filler to help "fillet" some areas
...& fill-in any gaps or imperfections

Then, did some sandin' (smoothin' & roundin')

Close up view of a "roughed in" fillet (just used my finger)

Close up view of a "rounded" fillet (after sanding)

Schmoosin' the quality control inspector "Ducky"
...durin' a quick brake