|JP Taping the nose cone|
|Costi taping a sidepod|
Next, we spray 3 coats of PVA on the molds as a release agent. PVA dissolves in water, so it's relatively easy to release the parts from the molds by apply water and force.
Finally, we can start layering the carbon fiber onto the molds. The process is pretty standard, but we have to make sure to lay up the top layer in a cosmetically pleasing fashion.
|Strategic cuts where you have small radii are important|
We also have to make all the cutouts in the pieces to make them fit over all the various things sticking out of our car. We have front wing cutouts, radiator support cutout, and the muffler support cutout. Finally, we can paint the pieces.
|Hard at work priming the bodywork|
|Finally, Duke blue bodywork.|
Of course, we have to attach the bodywork to the car too. We use Dzus fasteners most of the way around - and this year we've made use of industrial strength velcro to attach bodywork. The side panels are attached with Dzus fasteners across the top and velcro around bottom, the side pods attach to the side panels via Dzus fasteners on top and velcro around the bottom to the diffuser, and the nose cone attaches to the frame with one Dzus fastener on top and velcro to the front wing on the bottom (see the trend?). All those tabs had to be welded to the frame (I think right around here is when our TIG welder broke...)
And finally, the finished product before all those stickers go on.