Project Gallery: Novarace D Sports Racer Bodywork

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Ultra Lightweight Carbon Fiber Bodywork, From Scratch!

Designer Jay Novaks, Dennis Hamilton, Ton Shaver, and Mike Devins finished the Novarace D Sports Racer in time for SCCA's June Sprints.
Designer Jay Novaks, Dennis Hamilton, Tom Shaver, Mike Devins, and a bunch of friends
busted their butts to finish the Novarace D Sports Racer in time for SCCA's June Sprints.

Cockpit top and main body taking shape.
First a model is made. Moulds are made from the model. Then body parts are layed-up inside
the moulds. Here, the cockpit top and main body model is beginning to take shape.

Developing the engine cover shape in foam.
Developing the engine cover shape in foam.

The cowl and engine cover configuration in primer.
The cowl and engine cover model is shown here after being covered in primer.

Urethane foam fenders carved down to basic shape and then sealed with polyester resin and glass mat before surface work begins.
Adding the fenders to the model. They're urethane foam, carved down to basic shape
and then sealed with polyester resin and glass mat before surface work begins.

This shows the poly/mat coating over the foam.
This shows the poly/mat coating over the foam.

The model, all polished up!
The model, all polished up!

Another view of the polished model.
Another view of the polished model.

The rear diffuser and the undertray tools were removed previously, while the model was upside down.
The rear diffuser and the undertray tools were removed previously,
while the model was upside down.

A photo of the undertray.
A photo of the undertray.

A photo of the rear diffuser section.
A photo of the rear diffuser section.

Wheel arch parting lines.
Wheel arch parting lines.

Novarace D Sports Racer (DSR) project coming together in the Preform Resources workshop.
Novarace D Sports Racer ("DSR") project coming together in the Preform Resources workshop.

This shot shows how the parting lines were created.
This shot shows how the parting lines were created.


Here's Dennis Hamilton and one of Preform Resources workshop aids laying up the nose tool.

Nose and center top tooling, bolted together.
Nose and center top tooling, bolted together.

This photo shows the almost-complete Novarace DSR racecar body.
This photo shows the almost-complete Novarace DSR racecar body.
(The front, lower nose wasn't completed yet when this photo was taken.)

When this photo was taken, its rear diffuser and undertray had already been delivered.
Another almost-complete look at the Novarace DSR. When this photo was taken, its
rear diffuser and undertray had already been delivered, so they aren't shown here.

Here's the first carbon fiber body, shortly after its removal from the moulds.
Here's the first carbon fiber body, viewed from the rear, shortly after removal from the moulds.

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