armaautomotive

After the foam shape is cut I use different colors so when I sand to smooth the surface smooth I can tell if I’m removing too much of the surface. The red would be too close to the foam which is much softer and would loose its shape if sanded next to epoxy. After a few more coats and sanding it will start to become smooth.

More epoxy layers on the foam.

Painting layers of epoxy to create a smooth surface for the moulds. These are still ruff surfaces but after several coats it comes together.

It’s almost ready, our portable CNC plasma tube notcher makes building tube frame projects faster. We have a few pieces to finish but they should be ready soon and I can post more with sample projects. They are particularly good for automotive chassis and because it’s portable it packed away in the corner. I am curious to hear about projects you would build, comment or message your thoughts.

Preparing the foam surfaces with epoxy and fill to make them smooth.

Second side panel cut. Next the rear diffuser then interior panels.

One side panel cut, one to go.

Left rear quarter panel block done. This one took a while, after a failed attempt and router service this one is finally cut. Next are the two side skirts, then interior parts. The first try failed because the router Colette unscrewed itself mid run and my some miracle it didn’t break the machine.

One half of the rear quarter panel. This is one of my favourite parts of the car. The panel will lift as one large piece for service and cleaning. The foam is 2lb which is affordable and easy to cut but it’s not strong enough for a clean surface so I’m adding layers of epoxy before making moulds. It looks ruff but with more layers and sanding it will be smooth.

Here is the other side of the front hood. The mould will be split in two parts for a more manageable build process. The next two parts will be the rear quarter panels which are my favourite part of the car. The side skirts are being revised and will be done later then I have to cut the rear diffuser and then start on the interior parts. We will be selling moulds, tools and plans for builders to make these cars once we can finalize all of the pieces.