![](https://s3images.coroflot.com/user_files/individual_files/710639_qoq9wawwxx6u4ezdndvlcl_hk.jpg)
Once the design of the main body shape was settled, a profile was sent to a foam supplier to be shaped using a CNC.
![](https://s3images.coroflot.com/user_files/individual_files/710639_7f5wfvurzb0art7tsejebsa9y.jpg)
The surface of the mould and the sides were then prepared for a carbon fiber infusion process.
![](https://s3images.coroflot.com/user_files/individual_files/710639_ngofirurz0nilh6jsl6urh3ww.jpg)
Applying a release wax to the surface of the mould.
![](https://s3images.coroflot.com/user_files/individual_files/710639_ncrzgshgztmd3qsl3q5xua9hp.jpg)
The carbon fiber was layered into the mould, then baked to encourage drying.
![](https://s3images.coroflot.com/user_files/individual_files/710639_y5brllvg9ummvfiapdp9_uhnj.jpg)
The main body shape after the baking process.
![](https://s3images.coroflot.com/user_files/individual_files/710639_bflmhlmmplgtyn4b_zjphpjdt.jpg)
Reinforcing a few dry spots with extra resin using an infusion process.
![](https://s3images.coroflot.com/user_files/individual_files/710639_wkr9gkkampmkmt4whe22wq0bg.jpg)
Reinforcing a few dry spots using an infusion process.
![](https://s3images.coroflot.com/user_files/individual_files/710639__s8vd8dszcvw0quybtfvkq3xd.jpg)
Preparing a smooth clean table surface to create a custom carbon fiber panel.
![](https://s3images.coroflot.com/user_files/individual_files/710639_nwtiy5tsbpht777rjgky54lre.jpg)
Using an infusion method to create our carbon fiber panel. The material will then be shaped and used as a spar to provide additional strength to the vehicle.
![](https://s3images.coroflot.com/user_files/individual_files/710639_jfwpawbfyqegzwttvb3qtfmle.jpg)
Baking spars to speed up the drying process.
![](https://s3images.coroflot.com/user_files/individual_files/710639_tf4ygxes2lvsx5esnrl3dyuyh.jpg)
The carbon fiber panel we made that will be shaped into spars to provide additional vehicle stability/strength.
![](https://s3images.coroflot.com/user_files/individual_files/710639_gcdq5edvg8rof6pyahmct9jhk.jpg)
Leading edge of the vehicle.
![](https://s3images.coroflot.com/user_files/individual_files/710639_ptnxngfpzby7vcdi4dbi0acyp.jpg)
Shaping the profile for the carbon fiber spars.
![](https://s3images.coroflot.com/user_files/individual_files/710639_5xvf0_2ntuehq_ri9yeonnvc_.jpg)
The spars have been shaped and partially installed.
![](https://s3images.coroflot.com/user_files/individual_files/710639_vsom5flqqtjino3sahasjiabz.jpg)
Constructing a torsion box which was attached to the vehicle body and the spars.
![](https://s3images.coroflot.com/user_files/individual_files/710639_baxyyoh9akz_hkuhtzp9cmdsd.jpg)
Constructing a torsion box which was attached to the vehicle body and the spars.
![](https://s3images.coroflot.com/user_files/individual_files/710639_50gyg04sjrroarf7pgoeia8ff.jpg)
Wet laying the spars to the base of the vehicle to provide additional strength.
![](https://s3images.coroflot.com/user_files/individual_files/710639_v4fbsi5lgj3kexqhnoo6xntar.jpg)
Using an infusion method to secure the spars to the vehicle body.
![](https://s3images.coroflot.com/user_files/individual_files/710639_jcdg8yidwyyhyp_nwsyoqso4e.jpg)
Vehicle body with spars and torsion boxes attached.
![](https://s3images.coroflot.com/user_files/individual_files/710639_u0by7aqpmda0wodorgxhgdxvs.jpg)
To create the driver tub, a melamine mould was created and then the designed layers of carbon fiber/fiber glass and foam were used.
![](https://s3images.coroflot.com/user_files/individual_files/710639_xswzkouqdrnuzb4z9aojnlb3s.jpg)
Applying the layers to the driver tub mould.
![](https://s3images.coroflot.com/user_files/individual_files/710639_z2zc0ic2xl2mlb2vllsnxomyf.jpg)
Carbon fiber infusion for the driver tub.
![](https://s3images.coroflot.com/user_files/individual_files/710639_lz0lp6qjfpxgrhfst3lzuo64c.jpg)
Sitting the tub into the vehicle body.
![](https://s3images.coroflot.com/user_files/individual_files/710639_4hzqboiot2ygkwunkjzv94tqb.jpg)
Setting up a carbon fiber infusion to attach the driver tub to the inside of the vehicle.
![](https://s3images.coroflot.com/user_files/individual_files/710639_mbgfaw4jz6oqlpnqzln88ezck.jpg)
Result of using the carbon fiber infusion method to attach the inside of the tub to the side of the vehicle.
![](https://s3images.coroflot.com/user_files/individual_files/710639_2sdxhwwvtg28r6p72gzzjcfki.jpg)
Bottom surface of the vehicle body.
![](https://s3images.coroflot.com/user_files/individual_files/710639_vu3ghdkf8lmxqmiynxltqa73b.jpg)
View from the back of the vehicle.
![](https://s3images.coroflot.com/user_files/individual_files/710639_lnt6jo5p9l3zvne3fkltzbahr.jpg)
Using a wet lay carbon fiber process to secure the tub to the vehicle body. Strips of removable plastic were used to provide a smooth finishing surface.
![](https://s3images.coroflot.com/user_files/individual_files/710639_9svzqimxh7hhbdupsek9z8fqz.jpg)
Using multiple methods, we wetlayed the carbon fibre to attach the tub to the vehicle base. Ontop of the wetlay is a thick layer of fibre glass, which was used as a 'sponge'. These layers had a vacuum applied to it. These combination of methods help minimize the additional weight added during the wetlay process.
![](https://s3images.coroflot.com/user_files/individual_files/710639_bwjopr2jrjdvkyffzyim0uxod.jpg)
The result of the methods in the previous image.
![](https://s3images.coroflot.com/user_files/individual_files/710639_qbokxvvmhznbrdxzjuptrwjxa.jpg)
Isometric view of the front of the vehicle.
![](https://s3images.coroflot.com/user_files/individual_files/710639_sagjxn37lnwl5ook_b09j70f7.jpg)
Creating a frame which was then used to shape the fiberglass roof.
![](https://s3images.coroflot.com/user_files/individual_files/710639_69tgx5wqumyfobkhkzsmb74un.jpg)
Profile shape of the fiber glass roof.
![](https://s3images.coroflot.com/user_files/individual_files/710639_w40qg9ieqv6jiyimtjatutnxc.jpg)
Securing spars to the roof.
![](https://s3images.coroflot.com/user_files/individual_files/710639_qweduruwxv4nbvo4blpawbtef.jpg)
Using a special blend of resin and powder we made smooth surface where the roof will sit on the base.
![](https://s3images.coroflot.com/user_files/individual_files/710639_zlic8joqbqpqgsx8rjqp98zmj.jpg)
Using plastic to provide a smooth surface and to get the material to where its needed.
![](https://s3images.coroflot.com/user_files/individual_files/710639_fkgfhjmrci8di08bqdxwlvcj4.jpg)
End result of the area where the roof will sit onto the base.
![](https://s3images.coroflot.com/user_files/individual_files/710639_k59r6xo5ct0_ly6r5sivczk7o.jpg)
Custom made wheel mould that will be used to make a composite wheel.
![](https://s3images.coroflot.com/user_files/individual_files/710639_khkr4rrs9xvqqh53nbujvu8zs.jpg)
Inside face of the wheel mould.
![](https://s3images.coroflot.com/user_files/individual_files/710639_cm5hvbu4cnvn4b2uytx7xyrs2.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639_wnmyzc0txxm0vhs9yy4bksc7l.jpg)
The primary resin we used.
![](https://s3images.coroflot.com/user_files/individual_files/710639_iaculknaqvpv8jk8tqyx6w3fc.jpg)
The foam moulds we received from a supplier who had the CNC cut from designs we made. These moulds would go on to be used as fairings for the vehicle.
![](https://s3images.coroflot.com/user_files/individual_files/710639_q4exuyct8pcpfo8dgoecee39n.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639_erhexevaejy3vyqgqdhklep7q.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639_yl36gdyotdrwv3aybrqnvj3kc.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639_mby5oyrbovo8_lmwmymfovfjv.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639_7fi7vbvp9zstuj9eemd25cwbd.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639_ygz_5reou8gycpqrztjrpi9xh.jpg)
Paint Preperation.
![](https://s3images.coroflot.com/user_files/individual_files/710639_pto4umoscppn49xgt4kihhqys.jpg)
Paint Preperation.
![](https://s3images.coroflot.com/user_files/individual_files/710639_ldee8g3j7uhd0ntf_tkagweec.jpg)
Testing.
![](https://s3images.coroflot.com/user_files/individual_files/710639_p3bipqgjwkek6ljffc_sr429t.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639_pkniwb7et8tkqhghwhfriutse.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639_2p2mobyiviyrp6ebhtp0hynd3.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639_o3sbyugkp99mgefwm9sqioe8n.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639_ph7m4j9dl3es5sl7pjhisl3qw.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639__izpwv98ohaglrkxgrvomvfg3.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639__knpslbw3nzwkqspzllpwdf47.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639_edericedygeneqbxwocnsydlq.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639_33tze3sz77tsgbvnlrxbusp9e.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639_rtydjmwqfogzmjkpfk3ibobeb.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/710639_v9fckktiaio7tbqknjwt7p9vl.jpg)
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