Another Super 7

[Tompidom]

How is this even posible?......

[Scale-Master]

I am pretty close to being done with the master for the Weber carbs. There’s about 60 pieces to make this part, maybe a few more… The hardware will machined for each individual carb after I cast copies.

[Scale-Master]

I use Legos to make my mold frames. (The plug in the center of the tire master is made of Renshape.)

Not only are the Legos easy to work with and reusable, they also can be stacked to fit more molds in the vacuum/pressure vessel. This is the rim master on top of the tire master to cast the first half of the molds.

[Scale-Master]

Here is the mold and a casting from it for the outer rim for the wheels.

[MidMazar]

Mark what is renshape?

[Scale-Master]

Originally Posted by MidMazar

Mark what is renshape?

It is a type of resin-like foam (or is it foam-like resin…?). Think of it as a synthetic wood with no grain. Kind of like surfboard foam, but much tighter celled. It comes in different densities and can be carved, machined, sanded and even finish painted.

[Scale-Master]

Here is the first cast tire on the first cast rim outer. I cast both parts from molds I made off masters I created. The tire is hollow and easily stretches over the one piece rim. It is so soft and pliable that it should “squat” under the weight of the car.
Front:

Back:

[Scale-Master]

I’ve been casting centers for the wheels too. Still not sure which design I’ll use, the five spoke or the web, or maybe something different all together…

[Scale-Master]

Here’s the set of five tires and outer rims I have made for it. I’m ready to get back to part and pattern making. Prototype work is more rewarding than “production” work.

[Tompidom]

Oh mn those tires look fantastic, For you sir I'll take my hat off!!

[Scale-Master]

Time to start building the frame. I am going to make it slightly beefier than a standard Caterham or Lotus, I went with 1.5 inch square (scale size) tube for the main sections.
In this picture are the top section from the nose to about the cowl, the lower perimeter box for the passenger compartment, and two lower front frame rails, (partially bent).

[Scale-Master]

Main lower frame perimeter is soldered together…

Some bracing added… Still need to clean up the solder joints on them, after I add more pieces…

[Scale-Master]

More pieces added…

[Scale-Master]

More progress, not a bad day’s work as far as I’m concerned…
I used brass rod inserted and soldered inside the square tube (full length plus mounting points) for these vertical members for additional strength. And I drilled receiver holes into the frame for a positive fit too.

Tack soldered these parts to the top of the frame…

And then soldered them all together.
Top:

Bottom:

[Scale-Master]

More bracing made and installed…