DESIGN PROCESS


~Aerodynamics

The machining process of the raw foam taking shape into the sections of our teams molded aerodynamic fairing can be seen below.

Raw Foam being prepped for machining. Raw Foam curing before transport to machine shop

Raw foam stock compressed together after being bonded together with adhesive, prior to being shipped off to the machine shop where the mold will being to take shape.

Card-board Fairing Mock-Up Fairing Mock_Up #2

Sizing the fairings dimensions using card-board templates for a general outline of the mold. Also used to establish a clear line of sight for each and every rider.

  A look down the spline of the fairing   Sizing the fairing for the ideal seated position of the rider 

Foam Mold Cutting Surface Fairing Mold on the Haas Router

Foam Mold Section_1 Cut and Stack Mold Sections

2-Fairing Mold sections glued together Fairing side section being cut by the Haas Router

Nose portion of the fairing Fairing pieced together_1

Finished Foam mold coming to life

The finished mold awaiting bondo work and intensive sanding before the composite

lay up process can begin.




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