Rob Wood's ABS Plastic fairing project HPV for the projectile 2 lowracer

Rob Wood's ABS Plastic Streamliner Project

This page chronicles Rob's project to build a durable yet fast plastic fairing for his home built Projectile 2 lowracer. Rob is planning on building two versions of this body. One will be a trainer version that he can use to commute to work. This version will have an opening in the top to allow him to get in and out easily. The other will be a full race version with wheel fairings and a canopy.

Rob Wood is building the plug that he will use to mold an ABS plastic fairing for his Projectile 2 low racer. He will form the plastic over the male mold. Since the plug will have to get hot, he's building it out of wood. This pictures shows the plug after Rob cut a bunch of 2x10s to the approximate dimensions and glued them together.
After the boards are fastened together, Rob grinds them smooth with a seriously wicked blade mounted in his grinder tool. Rob says this tool makes short work of the forming.
Here's the right side plug after grinding the edges off and beginning the smoothing process.
This process makes a lot of sawdust!
The pictures below show the left hand plug after it has been formed. Rob applies wood filler to the plug to fill in the irregularities and get it aero-smooth. Rob says that it took him an afternoon's work of about 6 hours to make the half-mold. This will be a very compact streamliner, at about 7.5 feet long, about 28 inches high, and 17 inches wide. As you can see in these pictures, Rob is using the latest in streamliner design theory. Current thinking is that to keep the air a laminar as possible, the vehicle should continue to widen as far back as possible, then drop off into the tail through a smooth transition. 
As each plug half weighs about 250lbs, Rob uses an engine hoist to lift the left half of the plug up so he can join it with the right half. 
Here are the two halves joined. It's starting to look like a streamliner fairing!

Rob says if he can get a couple more weekends off in November he should be ready to form the ABS by Thanksgiving. 

Rob says: 
"I am going to make the canopy out of 2 halves just like the main part of the fairing. I will glue it together then cut a flat piece of Vivak and wrap it around. I am going to extend the canopy out in front of the handle bars so I can cut an NACA vent in line with my line of sight. I learned from riding my old Coroplast streamliner that I was always looking out the vent hole anyway when the canopy fogged up."
During a short break in the winter weather, Rob built the male molds for the canopy. In this picture you can see the (blue) template of half of the canopy. 
Rob cut, stacked, and glued the airfoil shapes to make the right and left half canopy molds. 
The airfoil section are placed next to one of the fairing plugs to create the mating surface. 
The canopy mold is rough shaped and built up more.
The canopy halves are joined and shaped with the grinder.
The canopy is sanded. All that is left to do is fill a couple of low spots with wood filler. 
Rob also included a picture of the framework that will hold the plastic in place over the main body male plug. 

Click on the picture for a bigger image.

The Bimba air cylinders pictured will pull the frame and plastic down to the table when the plastic is hot enough to form. Rob decided to use a vacuum to pull the plastic the rest of the way down to the table. As Garrie and Rob drove home from an HPRA meeting, Rob was convinced that pulling the plastic down with a vacuum would have less of a chance of ripping the plastic during the forming process.
More soon...  

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