Spawn Aerodynamics - Bullittes CF build thread.

[SpawnAeroJohn]

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.

[LiquidZ]

Originally Posted by wstar

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.

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

[DIGItonium]

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

[SpawnAeroJohn]

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

Uploading updates!

[SpawnAeroJohn]

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.


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.


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.


We taped and lipped the roof. And here I am waxing it.



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.


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.


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.


Me doing the hood.


Hood, bumper, and the roof complete with 6 thick coates.


And this shows how much we can do in such a tiny space.


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.

[racerxj17]

do you run your business out of your garage?

[spearfish25]

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

[LiquidZ]

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

[SpawnAeroJohn]

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

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.

[RCZ]

thanks for clearing that up.

[SpawnAeroJohn]

Originally Posted by spearfish25

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

Along with rear view mirrors that hook up to the back doors of cars for those who like to drive their car with the seat reclined to the max

juuuust kidding.

[SpawnAeroJohn]

Originally Posted by racerxj17

do you run your business out of your garage?

Originally Posted by RCZ

thanks for clearing that up.

Like I said we want a shop and have every intentions of moving into our own instead of splitting one + working out of the garage. But before we just did not need the space and we were dealing with a cramped environment. You know. Conforming to what is already given.

After a few of these part molds are finished and once we start getting orders we will be forced to move into at least 2000 - 5000 sq ft space because as you can already see. It is becoming very hard to move around in the current place. Tomorrow we are moving some stuff to the paint shop just so we have room to turn around with out elbowing each other in the face.

[jmlenz]

Please do us al la favor and weigh the stock parts (hood, hatch, bumpers, etc) so we have a starting comparison!

I removed the hatch a while back as well and it felt pretty light to me (compared to the steel 350z at least) but never weighed it.

Thanks for all the updates!

[LiquidZ]

Spawn, do you have any newly released drawings of what the final product or products are going to look like?

[wstar]

Originally Posted by LiquidZ

Spawn, do you have any newly released drawings of what the final product or products are going to look like?

I don't see why they would make a drawing, they're going to mold the original pieces, so it's not like it's done in CAD software or anything.

Ok so for this car, the roof is going to be an overlay, so we won't get a roof weight. The front stuff (fenders, hood) are going to be a complete replacement though right?