Spawn Aerodynamics - Bullittes CF build thread.
 

Today Bullitt (Mike) dropped his Z off at our shop. For what you ask? Well we are proud to announce we will be creating a bunch of carbon fiber parts for him and these parts will be available for the public!

The following parts will be created in the next 2 weeks. We will be uploading pictures constantly and updating you guys on what is ready to sell.

Carbon fiber hood (OEM or custom vented)
Carbon fiber hatch OEM
Carbon fiber fenders (OEM or vented / 20mm - 25mm wider)
Carbon fiber B pillars
Carbon fiber roof
Carbon fiber license plate backing
Carbon fiber duckbill spoiler
And possibly Carbon fiber rear bumper center lower overlay (around the tail pipes)

All CF parts will be made from the best quality epoxies and 2x2 weave carbon fiber.

Yes we have a short 2 week deadline but we will get if not everything, most of this finished. We are going to be working 10 + hr days to do this build so we can beat the other companies to the carbon fiber parts race.

Here are the pictures of Day 1 of 14
http://i623.photobucket.com/albums/t...Z/DSC_3792.jpg

http://i623.photobucket.com/albums/t...Z/DSC_3791.jpg

Ready... Set... GO!

P.S We will post pictures daily of our progress. If anybody has questions please feel free to PM me! No deposites are being taken and orders for these parts will be taken at a minimum so we do not get backed up.

UPDATE
Update! Day 2!
Progress : Everything stripped but hood and windows
Injuries : 1
Left to do : A whole lot!
More info and pictures are posted on Page 2 of this thread.

nice...good idea for an update thread...can't wait...let the races begin

this is going to become one of the most popular threads on this forum....lots of eyes watching...no pressure ;)

Subscribed for sure.

Interesting headlights btw..

In to see the progress, sure many are going to jump in here.

What is a duckbill spoiler? I would be interested in a front lip.

A duckbill spoiler is one that looks like it's actually coming out of the body... very common on Mustangs.

Just kickin back in the cut.

Can't wait to see the results!!

ready for pics! lucky Mike!

hehehe Thanks john! In for updates as well :D

The duckbill spoiler will be like an extension on the oem spoiler that is slightly taller in the middle.

Thanks bro! the headlights rock! thanks again to Igor and the guys over @ 180 custom!

Eager to see the wing extention and front lip!

+1

Any idea what kind of weight we could save with the hood?

We are not sure yet. Today was the break down day of the car for all the molds...

The car is already full aluminum, I'd really guess it's only about 5 pounds per part.

^ Even if it were 5 lbs a part (which I assume itl be more saved because they are still pretty heavy especially the hatch we took it off today) all together you are saving at least 40 + lbs.

Pictures coming today!

:yum:

today?

today is over...

Update! Day 2!
Progress : Everything stripped but hood and windows
Injuries : 1
Left to do : A whole lot!

So today we got in and started taking apart the car and studying the pieces so we are prepared to deal with the mold making tomorrow. We don’t know how many parts we can create molds tomorrow but we hope to get more accomplished then we think we can.

At least the roof, 2 fenders or the hood or the hatch.

Here are some pictures below with captions below that.

http://i623.photobucket.com/albums/t...2/SSPX1544.jpg

Since we were just starting I told my associate here to pretend he is doing something for a picture.

http://i623.photobucket.com/albums/t...2/SSPX1547.jpg
This is after we got the head liner removed, some interior panels, and the sarounding parts that go over the doors.

http://i623.photobucket.com/albums/t...2/SSPX1563.jpg
Rear hatch removed (not as light as everybody thinks)

http://i623.photobucket.com/albums/t...2/SSPX1559.jpg
Me removing the fenders.

http://i623.photobucket.com/albums/t...2/SSPX1562.jpg
Fenders and side moldings removed.

And at the end of the night we had this.
http://i623.photobucket.com/albums/t...2/SSPX1560.jpg

http://i623.photobucket.com/albums/t...2/SSPX1564.jpg

More coming tomorrow!

subscribed

rapedZ

just had to subscribe to this thread!

no she is being well taken care of :)

What??? :eek:

Are we talking about a removing sheetmetal kind of project?!?! Or is this simply an overlay?

EDIT: Never mind should have clicked to page 2. Niiiiiice.

naked Z right there

interested in the sideskirts too :)

Great thread :)

John: be sure to weigh the removed stock metal bits and the replacements when they're done, so we can see the weight savings per item.

Please don't make them as ugly as the stock ones.

Oh, and if you can make a front bumper that's not atrocious, you'll be..........................the first company to do so. :p

Yes the CF roof is an overlay. We dont think the side skirts will be replicated in CF. We had to remove them to get to the fender bolts. And we will be doing aero kits, but maybe after this 2 weeks. We will need another Z to come by for that.

We are currently working hard! We are just on a ramen noodle brake right now.

Yes. Please don't forget this and include pictures of the scale reading for proof.

Are you guys weighing in all the parts for comparison purpose? It would be of great value for the community.

We will be weighing them. We just need to finish the parts first :P

Uploading updates!

Day 3!

So far we got allot done. Not as much as we wanted to because a shipment of materials did not come in until 5PM. But we got some parts ready for molding tomorrow. Its 9PM and I’m going to go back out after this and do some more work.

We started the day by removing the hood and throwing the parts outside so we can have all the room in the world to strip them to start the molds.
http://i623.photobucket.com/albums/t...3/SSPX1580.jpg

Oh look! Here is me building the lip for the hood. The hood is the first one we want to do so that I can pull a replica out, modify it, and create a mold of that.
http://i623.photobucket.com/albums/t...3/SSPX1582.jpg

After the lip we put it back outside and sealed all the seams with Elmer’s glue. This makes sure that all the gaps are filled between teh tape and the hood so no materials run behind it and lock the part into the mold.
http://i623.photobucket.com/albums/t...3/SSPX1588.jpg

We taped and lipped the roof. And here I am waxing it.
http://i623.photobucket.com/albums/t...3/SSPX1591.jpg


He is waxing the bumper license backing plate so we can reproduce those in carbon fiber. We used news paper because our paper rolls weren’t going to come in until tomorrow.
http://i623.photobucket.com/albums/t...3/SSPX1592.jpg

Time for a ramen noodles brake and then after that spraying the parts down with PVA.
PVA is a material that comes in a liquid form, and once you brush, spray, wipe it on it builds up and turns into a saran wrap plastic material. This creates a great barrier so that the materials never actually touch the hood.
http://i623.photobucket.com/albums/t...3/SSPX1594.jpg

Here I am spraying it onto the hood (5th coat) Yes the car is poorly covered but this stuff dissolves with regular water. I’ve done this dozens of times in the past. This stuff will not harm anything and washes off instantly. You can dip a ball of this in water and it will melt in a second. Just FYI so nobody gets scared. P.S Yes the windows are closed and we will be cleaning the car as soon as the molds are parted just to be safe.
http://i623.photobucket.com/albums/t...3/SSPX1597.jpg

Me doing the hood.
http://i623.photobucket.com/albums/t...3/SSPX1601.jpg

Hood, bumper, and the roof complete with 6 thick coates.
http://i623.photobucket.com/albums/t...3/SSPX1604.jpg

And this shows how much we can do in such a tiny space.
http://i623.photobucket.com/albums/t...3/SSPX1608.jpg

More pictures coming tomorrow! Tomorrow we plan to finish at least 4 molds or more. Then start more molds. The next day while we are finishing those molds, these 4 will be ready to pull.

do you run your business out of your garage?

Love the front bumper Pepsi holder...hope that makes the production version :)

Looks like you guys are making some excellent progress. I'm very excited for your results.

The beginning process is done in my garage since we can work our own hrs. The end work (anything that involves paint, clear coating, or heavy sanding) is done at a shop 3 doors down where they have the spray booth and ventilation systems.

From when we started to now we would have rather been crowded in a garage and save on overhead than move to our own shop. But after these 2 - 3 weeks we are planning on either moving to a 2nd story warehouse shop which is about 5000 sq ft w/ freight elevator (located in the city) or a shop from a friend who is moving to a new shop.

Its not the place its the people who do the job :tiphat:

Mind you we have all the proper materials, tools, equipment, etc.

Since I started everybody tells us to stay here as long as we can. I look at it this way. Orange county choppers started in their basement for about a year before they got a shop.

Sorry to ramble I just don’t want people getting the impression that we dont know what we are doing.

thanks for clearing that up.