This is another multi part series. This is a long project for the 2007 ASME Human Powered Vehicle team from the University of Central Florida. I will be breaking up major tasks into smaller instructables as the entire process is gargantuan.
Here's a Botched together video. The fast paced part is 1 hour of work ;)
We're making an HPV! That's human powered vehicle ;) We are required to have at least 1/3 of our frontal area covered by a fairing (a fairing is just an aerodynamic shell -- like your car's outer skin). We're going for a fully enclosed (aka "sealed") fairing.
To tackle this manufacturing problem, we will be making a "female" negative mold. Similar to how casts of fish are made. To make this mold, we first need to make a positive "male" plug.
This instructable is a guide! I'm not going to instruct you on how to make the shape - there's plenty of resources on that. Instead, I'm providing rough instructions on how to start this task.
Our mentor currently works for Lockheed Martin as a model maker. When it comes to composites, this man knows his stuff. This is my third year working on this type of project, and he has provided a wealth of information and advice. If you'll be tackling a similar scale project - find yourself someone that has the experience to guide you in the right direction.