• Test fitting the rear fibreglass body panels – custom sports car build – Delta Ligero

    January 10th, 2017 | by
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    After the first lot of rear custom fibreglass body panels were successfully pulled out of the moulds, the crew at Joe Bradley Fibreglass carefully gave them a trim and a tidy, and cut out all of the areas that are going to be air intakes or mesh on the final car. Then it was time to test fit the panels onto the rolling chassis and get our first true impression of what the rear end of the Ligero will look like. 

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    The cut out areas in the rear panel of the car will have mesh inserted into them to vent air out the back of the engine bay. The circular depressions are naturally going to have the triple tail lights in them, and the lower, outer vents will have the dual exhaust tips vertically stacked on each side. Below is a cardboard mockup of the badge work for the rear of the car with the black cardboard representing the mesh.

    A small amount of remedial cutting and pasting of the side sills of the chassis was required for a perfect fit of the body.

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    Then finally the Ligero could be lowered from the stands to get a feel for its road stance. Naturally this will require a bit of fine tuning as the back end gets loaded up with the AMG 5.5L V8 and Porsche 996 transaxle. Another factor that we have considered is that the custom Bilstein shocks are designed for a Corvette C5, which is a front-engined car, so it will be interesting to see how they perform in the setting of a mid-engined configuration. Only time will tell.

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    The final component to test fit on the rear was the wing, which is currently still in its body plug stage. Here’s a sneak preview of how it is going to look, complete with one of the early edition of Delta badges!

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    And finally a walk around and description of the build to date with the prototype Ligero back at Trickey Performance Engineering. It’s back to Andrew now to work his magic again and continue to build.

    Until next time, cheers, dan.

     

    View Dan Pronk's profile on LinkedIn
  • First Ligero fibreglass bodywork panels revealed!

    January 1st, 2017 | by
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    In a significant milestone for Delta Automotive the first fibreglass rear bodywork panels have come out of the mould, and they look fantastic! The photos below are of the crew at Joe Bradley Fibreglass removing the moulds from the first fibreglass rear bodywork, clad in grey gelcoat. 

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    We couldn’t have hoped for a better result, and the rear moulds are now complete and ready to pump out further panels as required. Next step is to test fit the panels on the chassis. 

  • Rear fibreglass body panel mould creation

    December 24th, 2016 | by
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    With the rear plug finished to a perfectly smooth Mack Truck brown finish it could then be waxed with a bunch of coats and clad with the gelcoat and the fibreglass that would then be removed to form the moulds for the rear body panels for the Ligero. 

    The process is outlined in the video below – First of all a thick coat of black gelcoat is sprayed onto the waxed rear bodywork plug. The wax ensures that when the time comes to release the mould that it will separate at the gelcoat layer. The gelcoat allows for a perfectly smooth finish on the inside of the moulds for the panels. Once the gelcoat is appropriately dry, fibreglass is laid over the top of it to create the rigid structure for the moulds. 

    Everything is then left to cure with a few strategic pieces of wood for reinforcement and rigidity, and some carefully made separations in the mould to allow the mould to be strategically released in pieces. 

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    Once cured these mould pieces will be removed from the plug and then the process of creating the first rear body panels will begin. The plug itself will then become largely obsolete, which seems a shame after all of the hours of hard work that went into it. One of the crew at Joe Bradley Fibreglass suggested that it could be turned into a barbecue or a home bar! What do you think?