re: building full scale car body ???

From: William D. Richards (
Date: Sat Jul 03 1999 - 00:51:22 EEST

        It would be possible to use a CNC machine to carve out a foam core.
It's done in homebuilt aircraft fairly often. You can do the in pieces, and
assemble them to create your core.
        I would like to hear from my fellow RPer's in the automotive
industry to confirm or deny this, but don't a number of automobile
manufacturers have large-scale CNC machines that can carve out a 1:1 foam
core in one shot?
        A more likely -- and less expensive -- route to follow would be to
use a plotter to print up full-scale profiles, and use these as patterns to
cut the foam by hand, and then fill the gaps and hand contour your model.

        Good luck! I'd like to see what other suggestions come up...

Bill Richards
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>Hi.....I am interested in building a 1:1 scale car body.
>Its the " missing link " as it was a prototype series of 30 that was
>destroyed in the late 1930s.
>I probably can get the cad file but need more info on how to proceeed.
>I was thinking of making a plywood model, sections every foot or so , then
>fill with foam and finish contouring. then fiberglass over the finished plug.
>Would love to do the final body in metal , but here in California that would
>be very expensive.
>Any suggestions or schools that would like to take on a project like this ?
>thanks for your help........Chris
>For more information about the rp-ml, see

For more information about the rp-ml, see

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