|The first few pieces of the bodywork molds|
It's snowing in Durham, NC
Over the next couple weeks, I'll do a reasonably detailed writeup of the process. The first steps are to prepare the bodywork molds from the CAD models.
The way I modeled the bodywork was using surfaces. Though I don't think mastercam really has too much of an issue with surfaces, I solidified all the surfaces into solids by extruding up to the surfaces. The easiest way to do this in my opinion is to use convert entities to project the outline of the surface onto your sketch plane, and then extrude up to the surface. There are always issues with extruding up to surfaces; the most common are gaps in the surface, the boundary of the extrude not being consistent with the surface, gaps in the sketch from selecting the wrong edge when converting entities, etc. Sometimes it's easier just to offset the outline inwards a little bit if the problem with the extrude is at the boundary.
|extrude up to surface|
We purchased the foam from Universal Foam, who got us the 2lb EPS very quickly (5 days from when we ordered to when we received shipment) and at a great price.
|Pallet of foam- we put some of it in the garage already. This is what wouldn't fit in the garage.|
|Toolpath for one of the blocks. First, I face the part of the material that's not used. Next, I surface the flatish surface, and finally I cut the outside contour.|
Removing the part tends to be a bit more difficult than putting it on. The trick is to slide something thin and sharp between the wood and the foam block (we used the blade of our wood saw, which worked very well) to break the tape and pry the foam off of it. Then, clean up the tape on the wood (which can be difficult, because it's so thin and tacky). Eventually, the tape will pile up to the point where you'll have to face off the wood board.
Needless to say, foam did start piling up in the garage very quickly. It's a mess in there right now, and it's going to stay that way until the bodywork molds are finished.
|The beginning of the night. Notice how (sort of) clean the garage is.|
|Milling the first piece. Starting to get a little bit white.|
|Taking the first piece off|
|after the third piece|
|A little while later|
|At the end of the night|
|First piece finished|
|First piece again|
|First two pieces|