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I think we need some sort of plasma ray

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so we don't have to run tires

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and just build a hovercraft.

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Dave: We're working on the very first of its kind

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at kindig-it design --

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a concept production vehicle.

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Alright. Let's do it.

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It's brand new,

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but we're cutting it apart.

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What we don't want to do is build a plug car,

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send it up, have the mold pulled off,

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and then we find out the plug car was twisted,

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and then every one of our cars are gonna be that way.

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Whoa!

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I like to smash his fingers! Smash his fingers!

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what am I going to do with this guy?

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Dave: Clean...

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Custom...

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Bitchin'.

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my name is dave kindig.

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Designing and building custom cars is my life's passion.

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With the best mechanics, technicians, and fabricators

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in the business, quality is our only focus.

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We build bitchin' rides.

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-- Captions by vitac -- www.Vitac.Com

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captions paid for by discovery communications

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Watch Online Movies and Series for FREE
www.osdb.link/lm

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I've always wanted to build a one-off car

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that I could do a series of them

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and have them all very special for individual clients.

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Perfect example -- the very first year of corvette, 1953.

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I've always been a huge fan of that car.

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Doing my little twist to it, though,

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I think it's going to be over the top bitchin'.

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So, my plan today is to try and create

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a retro-styled modern classic of a corvette.

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Now, the very first year of the corvette was 1953,

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and this, in particular, body style of corvette

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is actually my very favorite

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because it has a lot of european twists,

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with the domed headlights, the sweeps of the body.

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It just has a really, really cool look,

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and I've got an idea of how to make this work.

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If you look at the overall height of the body

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and the front, basically the body

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seems to get larger in the front than it is in the rear,

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and one of the common problems with this car

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also that we're going to try and fix

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is the fact that you really can't sit in the car

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if you're taller than 5'5".

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So, a couple of things I think I'm going to do --

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we will actually take

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three inches in the front

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out to zero.

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I want to increase the size of the wheels,

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and I'm really thinking

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about raising the wheels wheels up in that bottom line.

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Another thing -- we really want to open up that interior.

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I think if we were even to increase the length of the door,

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but not the wheel base by three or four inches,

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I think we'd be in really good shape.

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So now, a normal sized person can sit in the car.

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With that, kids,

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let's get our magic scissors and start cutting.

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but that is slick.

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I think what I'll do is go ahead and draw it.

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The color combination I'm putting on this one

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is just so I can kind of see what the shape of the car is.

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Just getting an idea of quick color,

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shows off the shape of the car,

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and I'm really liking what I'm seeing here.

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With this concept, basically, we're wrapped,

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and I really think that the car looks great,

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and more so, I think that I'm convinced

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that this will be a great car.

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I think the next thing I'm going to do

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is I'm gonna call my buddy jerry up a corvette image

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and see if I can get some parts and slap one of these together

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and start chopping it up.

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I'm digging it.

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This one's going to be a really good mix of old and new

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or modern and classic

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to really come up with something that's going to be awesome

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as a first turnkey kindig-it design car.

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Alright.

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So, it is a 1953 corvette,

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but I've moved a lot of stuff around.

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I'm kind of inspired, man.

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I think this is going to be really a dope car.

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Remember the last time you were inspired?

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Yeah, I know. It was great.

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Sounds like a lot of work for us.

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Yeah, it was a lot of work for us last time.

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well, now, remember what I always say --

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if it was easy, everybody would do it

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and then it just wouldn't be that cool.

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Right? I get it. I get it.

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I've got a body coming in,

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but I want to build more than just one of these.

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So, this first car, let's chop it up.

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Let's do all the changes that we want to do.

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Let's make it perfect, and let's pull molds off of it

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and we'll produce these cars.

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How many are you thinking about making?

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Well, I actually have a couple of guys

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who are already interested in the first two,

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so -- and I think I'll have to have number three.

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So, three to start.

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I think making a concept car

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out of a c-1 or c-1s is amazing.

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Do I think we have time to do it right now? No.

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Sounds like a lot of work.

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Sounds like he wants us to build him a car.

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I really love the idea of a one-off concept

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kindig vehicle.

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If it's completely custom,

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it's something that's not on the road,

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something that only we build, and we build awesome cars.

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This is like that next step above.

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I'm thinking right now, mini cooper headlights,

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and I've actually got a set that's been kicking around

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that we can just try on there, see if it's going to work.

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Is this longer here?

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No. I'm taking three inches from here to zero.

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I'm going to wedge that whole car.

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That lowers the rear section and it lowers the nose,

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even though I'm gonna keep the nose the stock height.

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What about the compartment? I mean, these aren't big cars.

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Is a normal guy, like, my size going to fit,

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or is this only for your size?

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Well, you're only, like, what? Two inches taller than me?

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Okay, whatever.

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So, my point is we're opening up the cab

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and I'm figuring probably

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we'll get a better idea once we look at it.

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But usually, about a four-inch stretch. The cabinet is --

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like the '62. Exactly.

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But what I'm going to do, too, is those doors are so short,

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we have plenty of room back here.

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Let's just stretch the door and make it look

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proportionate to the car.

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Okay. You know what I mean?

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I don't know if I've ever heard of another hot rod shop

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doing a custom concept

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and bringing in a production as multiple cars.

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So, I mean, that's something unique in itself.

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What kind of power plants are you thinking?

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Just a variety?

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Basically, sky's the limit. We can do whatever we want.

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Build your own car, pick your motor.

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And I want each one very unique.

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Custom colors -- we'll develop those.

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Themes for interior, exterior.

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Really, when you start building the first one,

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the second one is right next to it.

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After you've done those two,

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the third one pretty much builds itself.

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Isn't that the one that dave wanted?

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The third one? That's right.

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You can build it yourself, then.

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If it pretty much builds itself.

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Well --

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you know what?

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first thing's first for these concept corvettes --

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we need to have it on a perfect foundation.

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That's why the roadster shop's building us a chassis,

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a spec chassis, to be exact.

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The really cool thing about these roadster shop spec chassis

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is they're actually designed to fit on a c-1 corvette,

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which is the first series.

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Well, much like any kindig-it design car,

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it's a mix of the old and the new.

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So, a c-1 corvette from 1953,

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but with all modern suspension out of a c-6 corvette

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from the early 2000s.

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Not a bad gig.

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alright, rob, we'll just throw it at this spot

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right here for a minute.

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this is a brand-new c-1 suspect chassis.

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What's really trick on these is we've got all c-7 suspension,

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the front rear spindles, a-arms,

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all of that's off of a c-7 corvette,

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so it's all factory. Really kick-butt stuff.

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What's going to be really cool

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is we've got rid of the trans axle

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and it now has a standard center section.

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This is basically a dana 60.

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Whoo! This is pretty.

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Sucks.

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Come on. It's not even a volkswagen.

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You have no room to complain at all.

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You have a paycheck coming.

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Man: So, this is what we're starting with,

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to build the prototype

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for the new kindig '53 corvette.

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Alright. Let's do it.

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We are starting with a 1953 corvette,

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so I need every body panel that would create that,

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and then I'm going to glue it together

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and then we're going to cut it apart.

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Where are we going?

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And there's going to be a ton of modifications

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to this stock body.

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The very first thing that we need to do

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with our concept-style corvette is chop it up.

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some of the big changes and the common things

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that were wrong with the '53 corvette

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is nobody over five and a half feet

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actually fits in the car.

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So, we're going to add four and a half inches

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of length to the cabin.

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We're also going to drop the seats down four inches

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between the frame rails.

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This is going to allow a much taller person to sit in the car

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and be very comfortable.

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We're going to cut off whatever we need to to get this body

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fitting on the chassis to begin with,

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but at the end of the day,

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we're going to build an entirely new floor.

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The idea on this concept car

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is to not stretch the wheel base,

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but to rather just stretch the door.

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This will give a more proportionate

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look to the door itself

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and also make it easier to get in and out of.

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okay, guys, well, thanks for coming over.

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The idea here is get a game plan.

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So, a couple of things that definitely need to happen.

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I sat in the car the other day.

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It's poobahs unless I'm laid way, way down.

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So, we need about a four-inch drop in the seat pans.

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We've got enough length in the car now

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to where it's going to be comfortable.

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We just need to get the height right.

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We have a fixed driveline that doesn't move

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because it's independent.

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So, we can put the exhaust underneath.

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We're going to definitely have to find somewhere tricky

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to put some...

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Mufflers. ...Some mufflers.

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The fuel tank's now going to go on the back

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that will's going to develop.

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We'll figure out how many gallons we can get in there.

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Well, and I figured it out with just the space that we have,

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and depending on how wide you make it,

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it's anywhere from 16 to 24 gallons already.

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Yeah. And without too many mods.

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I think 16 being the minimum

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would probably be the best. Yeah.

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I mean, if you think about it, if you keep your foot out of it,

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you're going to get over 22 miles to the gallon at least.

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-Right? 24? -20 miles a gallon.

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So, as soon as we get the wheels and tires back

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from getting mounted,

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what I want to do is set the wheel in place.

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Let's get a marking. Let's go ahead and open the wheel wells

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so that we know where the stance of the car is.

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I think it's important also at that point that we go ahead

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and get the mockup done on the ground

260
00:10:21,650 --> 00:10:23,180
so we can actually see the car at the stance

261
00:10:23,190 --> 00:10:24,680
with the wheels and everything else.

262
00:10:24,690 --> 00:10:26,690
What we don't want to do is build a plug car,

263
00:10:26,690 --> 00:10:28,490
send it up, have the mold pulled off,

264
00:10:28,490 --> 00:10:30,120
and then we find out the plug car was twisted

265
00:10:30,130 --> 00:10:33,060
or has a funny left or right deal,

266
00:10:33,060 --> 00:10:34,930
and then every one of our cars are going to be that way.

267
00:10:34,930 --> 00:10:38,100
So, we got to make sure that it's spot on.

268
00:10:38,100 --> 00:10:40,200
Looks good. See you next Friday.

269
00:10:40,200 --> 00:10:41,300
See you next Friday.

270
00:10:41,300 --> 00:10:42,540
Think we can have it done next Friday?

271
00:10:42,540 --> 00:10:44,600
No, I'm just leaving until next Friday.

272
00:10:44,610 --> 00:10:45,510
What?

273
00:10:49,080 --> 00:10:51,380
Since kevin apparently is going to take the next week off,

274
00:10:51,380 --> 00:10:53,250
I'm going to get will to modify this chassis.

275
00:10:53,250 --> 00:10:55,080
Will: We were super hoping that this spec chassis

276
00:10:55,080 --> 00:10:57,420
was going to just be perfect for everything.

277
00:10:57,420 --> 00:11:00,090
On paper, it looks great. Proof is in the pudding.

278
00:11:00,090 --> 00:11:01,450
You got to get it in front of you

279
00:11:01,460 --> 00:11:04,390
and then make the mods to it to really make it happen.

280
00:11:04,390 --> 00:11:07,490
It's brand-new, but we're cutting it apart.

281
00:11:07,500 --> 00:11:09,860
We needed to make some room

282
00:11:09,870 --> 00:11:13,030
so we could put the seat pan down inside the chassis.

283
00:11:13,040 --> 00:11:14,430
Basically, the bottom of the seat will be

284
00:11:14,440 --> 00:11:15,640
at the bottom of the chassis

285
00:11:15,640 --> 00:11:17,170
instead of the top of the chassis.

286
00:11:17,170 --> 00:11:22,040
My goal today is to get this outer rail moved out,

287
00:11:22,040 --> 00:11:26,680
move this cross member back to this juncture,

288
00:11:26,680 --> 00:11:28,450
move these in-board.

289
00:11:28,450 --> 00:11:29,950
So then, all of a sudden, you'll see

290
00:11:29,950 --> 00:11:34,020
we'll have a big pocket here for your bum to sit down in.

291
00:11:51,010 --> 00:11:53,240
we don't want to cut away too much material.

292
00:11:53,240 --> 00:11:56,340
So ultimately, I'm going to move some of the material out-board,

293
00:11:56,340 --> 00:11:57,940
some of the material in-board,

294
00:11:57,950 --> 00:12:00,280
some of the material forward,

295
00:12:00,280 --> 00:12:02,420
but we're going to keep this chassis strong.

296
00:12:14,030 --> 00:12:16,130
with all these mods made to this support beam,

297
00:12:16,130 --> 00:12:18,130
I just need to weld it back on the chassis.

298
00:12:25,870 --> 00:12:27,510
after a lot of welding,

299
00:12:27,510 --> 00:12:30,040
the chassis is still the right shape.

300
00:12:33,620 --> 00:12:37,450
New wheels for the mock up on the corvette are here,

301
00:12:37,450 --> 00:12:39,550
so we're going to check them out.

302
00:12:39,550 --> 00:12:41,490
Give them a little test fit before we send it over

303
00:12:41,490 --> 00:12:43,690
to get the tires put on them.

304
00:12:43,690 --> 00:12:47,090
And these are 22s? This is a 22x12.

305
00:12:47,100 --> 00:12:48,800
If we can get it out. If we can...

306
00:12:48,800 --> 00:12:50,600
Come on, baby.

307
00:12:50,600 --> 00:12:51,730
Why is it so stuck?

308
00:12:51,730 --> 00:12:53,630
I don't know. 'cause it's a 22.

309
00:12:53,640 --> 00:12:56,670
It's 22-inch wheel in a 20-inch box.

310
00:12:56,670 --> 00:12:59,140
I'm guessing.

311
00:12:59,140 --> 00:13:01,010
You know, I love having will a part of this team.

312
00:13:01,010 --> 00:13:04,610
He is so sharp. He is a big part of it and I love him.

313
00:13:04,610 --> 00:13:07,680
I think we need some sort of plasma ray

314
00:13:07,680 --> 00:13:09,850
so we don't have to run tires.

315
00:13:09,850 --> 00:13:11,480
But I think he's been in the shop too long.

316
00:13:11,490 --> 00:13:14,150
I think that maybe the fumes are getting to him.

317
00:13:14,160 --> 00:13:15,660
And just build a hovercraft.

318
00:13:34,940 --> 00:13:37,810
we're creating a plug car to pull molds off of

319
00:13:37,810 --> 00:13:40,750
for our 1953 concept-style corvettes,

320
00:13:40,750 --> 00:13:42,220
and since I'm the designer,

321
00:13:42,220 --> 00:13:45,350
I can choose whatever size wheel I want to, and I'm going big.

322
00:13:50,890 --> 00:13:54,030
I think we need some sort of plasma ray

323
00:13:54,030 --> 00:14:00,270
so we don't have to run tires, and just build a hovercraft.

324
00:14:00,270 --> 00:14:01,430
You know I'm going to start drug testing

325
00:14:01,440 --> 00:14:03,800
next month, right? Aw, man.

326
00:14:03,810 --> 00:14:06,540
it opens your mind. What?

327
00:14:06,540 --> 00:14:08,710
Like I need to be on drugs to come up

328
00:14:08,710 --> 00:14:09,680
with stuff like that.

329
00:14:09,680 --> 00:14:11,710
Are you good with that thing?

330
00:14:11,710 --> 00:14:13,450
I don't know. Am I?

331
00:14:13,450 --> 00:14:15,150
You might be all right. Are you good with it?

332
00:14:15,150 --> 00:14:17,120
That's the better question.

333
00:14:17,120 --> 00:14:18,750
We're not going to find out.

334
00:14:18,750 --> 00:14:20,090
Don't want to get dirty, huh?

335
00:14:20,090 --> 00:14:21,960
Well, I don't mind getting dirty.

336
00:14:21,960 --> 00:14:23,460
Look.

337
00:14:23,460 --> 00:14:24,760
Aw. Look at my shoes.

338
00:14:24,760 --> 00:14:26,290
That's so sad. But I'm not getting itchy.

339
00:14:26,290 --> 00:14:28,460
Not today. I didn't really plan for it.

340
00:14:28,460 --> 00:14:29,900
I don't have a scuba suit.

341
00:14:29,900 --> 00:14:32,330
Does "not today" mean at some point in the future you are?

342
00:14:32,330 --> 00:14:34,630
I'm going to definitely at some point --

343
00:14:34,640 --> 00:14:36,600
I'm going to get itchy on this car with you,

344
00:14:36,610 --> 00:14:39,410
and it'll be like a brotherhood of itchiness.

345
00:14:39,410 --> 00:14:41,270
Okay. I'm waiting for that day.

346
00:14:41,280 --> 00:14:43,510
Okay, don't hold your breath.

347
00:14:43,510 --> 00:14:45,110
I'm not planning on it.

348
00:15:01,600 --> 00:15:03,630
oh, geez. Those are heavy. Yeah.

349
00:15:03,630 --> 00:15:05,060
Solid stock.

350
00:15:10,140 --> 00:15:12,540
Dave: Those are pretty cool. That's going to be sick.

351
00:15:12,540 --> 00:15:14,810
Hey, you know what? To answer your question --

352
00:15:14,810 --> 00:15:17,980
you aren't bad with that electric thing.

353
00:15:17,980 --> 00:15:19,610
Jason: I've had a few hours behind it.

354
00:15:19,610 --> 00:15:21,250
With the wheels mocked up on the car now,

355
00:15:21,250 --> 00:15:22,850
it's time for will to get after

356
00:15:22,850 --> 00:15:25,390
building that floor on the chassis.

357
00:15:25,390 --> 00:15:28,090
Will: I've been playing on the computer, designing up

358
00:15:28,090 --> 00:15:30,920
as much of this floor as I could possibly, you know, get,

359
00:15:30,930 --> 00:15:33,090
trying to pay attention to, you know,

360
00:15:33,090 --> 00:15:37,030
the space from the frame to the floor,

361
00:15:37,030 --> 00:15:39,000
room in the tunnel.

362
00:15:39,000 --> 00:15:41,940
Yesterday, I cut all the panels, and I'm bending them,

363
00:15:41,940 --> 00:15:44,370
fitting some pieces.

364
00:15:44,370 --> 00:15:45,970
So essentially, what I've come up with

365
00:15:45,970 --> 00:15:48,510
is this giant puzzle

366
00:15:48,510 --> 00:15:52,550
that's going to be a buck for our fiberglass floor.

367
00:15:52,550 --> 00:15:54,850
The trick is to get it very seamless.

368
00:15:54,850 --> 00:15:57,520
So, all of a sudden, we have a whole complete floor

369
00:15:57,520 --> 00:16:01,090
and the body panels can drop right on here.

370
00:16:01,090 --> 00:16:04,460
It'll be really easy for them to build the body off of it.

371
00:16:04,460 --> 00:16:06,330
Used as many times as we need to.

372
00:16:06,330 --> 00:16:09,400
Hopefully, we'll sell a zillion of these cars.

373
00:16:14,640 --> 00:16:16,570
now, I think I'm going to do the same thing,

374
00:16:16,570 --> 00:16:19,840
add a couple little pieces, mainly spacers,

375
00:16:19,840 --> 00:16:23,240
so that I know that everything's running really true.

376
00:16:25,650 --> 00:16:30,780
What I'm after is three-and-three-quarter radius.

377
00:16:30,790 --> 00:16:34,120
What I have is totally wrong.

378
00:16:34,120 --> 00:16:36,260
So, usually when you get the stuff mapped out,

379
00:16:36,260 --> 00:16:38,320
you don't want to make a mistake.

380
00:16:38,330 --> 00:16:42,600
If you have one, it can lead into multiple.

381
00:16:42,600 --> 00:16:44,730
What a dummy.

382
00:16:44,730 --> 00:16:47,630
What I have is three-and-a-half-inch diameter,

383
00:16:47,640 --> 00:16:48,770
so that's totally wrong.

384
00:16:48,770 --> 00:16:50,570
So, let's go see how it looks on the car

385
00:16:50,570 --> 00:16:51,940
and what I'm going to have to do

386
00:16:51,940 --> 00:16:55,140
to remedy my over-tight bend that I just put in there.

387
00:16:55,140 --> 00:16:56,610
You really don't want to move ahead

388
00:16:56,610 --> 00:16:58,910
if you know you've got something wrong.

389
00:16:58,910 --> 00:17:04,050
It causes you to just do everything essentially wrong.

390
00:17:04,050 --> 00:17:05,650
We can do that easy enough.

391
00:17:14,400 --> 00:17:16,230
now, look.

392
00:17:16,230 --> 00:17:19,100
We're kind of trapped between a rock and a hard place.

393
00:17:19,100 --> 00:17:20,970
I have two pieces that go right here,

394
00:17:20,970 --> 00:17:23,000
so let's see how well they're going to fit.

395
00:17:23,000 --> 00:17:24,470
I had this whole thing mapped out,

396
00:17:24,470 --> 00:17:25,870
so if I can't get this piece to work,

397
00:17:25,870 --> 00:17:27,710
I'm going to have to re-bend this whole thing.

398
00:17:36,920 --> 00:17:40,190
I think we're okay with the radius and diameter situation.

399
00:17:40,190 --> 00:17:41,790
I was able to get everything figured out,

400
00:17:41,790 --> 00:17:46,130
but there's one last change I want to make to this floor.

401
00:17:46,130 --> 00:17:48,900
We need it to dip down where the seats go.

402
00:17:57,810 --> 00:17:59,440
with the seats being dropped down four inches,

403
00:17:59,440 --> 00:18:01,170
somebody taller can fit in this

404
00:18:01,180 --> 00:18:02,340
without their head sticking out of it,

405
00:18:02,340 --> 00:18:03,880
like the poobahs.

406
00:18:03,880 --> 00:18:05,210
The floor looks great,

407
00:18:05,210 --> 00:18:06,750
but I'm still a little bit worried about will.

408
00:18:06,750 --> 00:18:08,510
we're gonna have a class today

409
00:18:08,520 --> 00:18:10,220
on how to beat your head against the wall.

410
00:18:15,590 --> 00:18:18,020
so, I have to build a set of tubs

411
00:18:18,030 --> 00:18:19,360
for the '53 vette.

412
00:18:19,360 --> 00:18:20,690
It's kind of cool

413
00:18:20,700 --> 00:18:23,960
because I basically built them in the computer first,

414
00:18:23,970 --> 00:18:26,070
and the reason why I built this buck is because

415
00:18:26,070 --> 00:18:30,100
there's a pretty specific shape, big radius on this inboard side.

416
00:18:30,110 --> 00:18:31,870
Now, I know that there's going to be

417
00:18:31,870 --> 00:18:33,510
a little bit of adjustment

418
00:18:33,510 --> 00:18:35,910
how it comes and meets the wheel well.

419
00:18:35,910 --> 00:18:37,780
We're going to get the majority of it done.

420
00:18:37,780 --> 00:18:39,210
This could just be straight,

421
00:18:39,210 --> 00:18:41,250
then this has to be shrunk.

422
00:18:41,250 --> 00:18:42,980
It could wrap around the piece.

423
00:18:42,980 --> 00:18:44,420
Then to get this other side,

424
00:18:44,420 --> 00:18:46,350
we're going to go ahead and throw this on here.

425
00:18:52,690 --> 00:18:55,130
But as this rotates side to side,

426
00:18:55,130 --> 00:18:57,760
it's going to kind of follow a circle.

427
00:18:57,770 --> 00:19:02,340
So, one, we're going to do the cylinder on the english wheel.

428
00:19:02,340 --> 00:19:05,000
Basically a rubber band around the top dye

429
00:19:05,010 --> 00:19:07,010
so it just pushes the shape into it.

430
00:19:07,010 --> 00:19:09,540
It'll just make it cylindrical

431
00:19:09,540 --> 00:19:13,380
so that it will wrap all the way up around this radius.

432
00:19:13,380 --> 00:19:16,350
We don't want any shape in this section past there.

433
00:19:16,350 --> 00:19:18,350
So, we're going to roll right up to this.

434
00:19:30,300 --> 00:19:31,600
this is our big shrinker,

435
00:19:31,600 --> 00:19:34,670
and you'll see it does a hell of a job.

436
00:19:57,690 --> 00:20:00,460
okay. I got this fitting like I like.

437
00:20:00,460 --> 00:20:01,760
Now what I need to do

438
00:20:01,760 --> 00:20:05,160
is make a top panel, same radius along here,

439
00:20:05,170 --> 00:20:08,500
then I can trim this in and weld it right here.

440
00:20:14,840 --> 00:20:17,140
hello. I'm mr. Hammer.

441
00:20:17,150 --> 00:20:19,850
And I like to play in the puppet show.

442
00:20:19,850 --> 00:20:23,880
And then sometimes, when my friend mr. Glove is around,

443
00:20:23,890 --> 00:20:27,450
I like to smash his fingers! Smash his fingers!

444
00:20:27,460 --> 00:20:29,660
what am I going to do with this guy?

445
00:20:32,490 --> 00:20:34,790
Dave: We're working on the very first of its kind at kindig-it design,

446
00:20:34,800 --> 00:20:36,130
a concept production vehicle.

447
00:20:36,130 --> 00:20:38,000
Will just finished up with the wheel tubs and the floor.

448
00:20:38,000 --> 00:20:38,970
Will: Alright, cool.

449
00:20:38,970 --> 00:20:41,170
Got these all done, welded up.

450
00:20:41,170 --> 00:20:43,140
Now I just got to shove them in.

451
00:20:49,180 --> 00:20:51,110
okay, cool. There's one.

452
00:20:56,680 --> 00:20:59,490
well, that's cool.

453
00:20:59,490 --> 00:21:00,790
That's awesome.

454
00:21:00,790 --> 00:21:02,190
I need to get this over to the body side

455
00:21:02,190 --> 00:21:03,820
so they can do their part.

456
00:21:07,200 --> 00:21:09,030
Dave: Hey, so it looks like you're putting a car together here.

457
00:21:09,030 --> 00:21:10,300
I was trying. You got it over

458
00:21:10,300 --> 00:21:11,360
into the next stage, huh?

459
00:21:11,370 --> 00:21:12,600
Yeah.

460
00:21:12,600 --> 00:21:14,570
It's looking pretty good there.

461
00:21:14,570 --> 00:21:17,600
Got the glue flange right here for the tub to go in.

462
00:21:17,610 --> 00:21:19,910
This will give us adjustability again to be able to put it

463
00:21:19,910 --> 00:21:21,010
wherever it needs to go.

464
00:21:21,010 --> 00:21:22,170
I tried to make the floor piece,

465
00:21:22,180 --> 00:21:25,950
like, kind of as big and as complete as possible.

466
00:21:25,950 --> 00:21:27,750
We need this very first car to be perfect

467
00:21:27,750 --> 00:21:29,480
because we're pulling molds off of this car.

468
00:21:29,480 --> 00:21:30,950
He doesn't have to pull a mold off of this.

469
00:21:30,950 --> 00:21:32,220
This is the mold.

470
00:21:32,220 --> 00:21:33,620
Yes. It's going to be awesome.

471
00:21:33,620 --> 00:21:34,990
Yeah. Everybody was kind of confused

472
00:21:34,990 --> 00:21:36,720
and scratching their heads wondering what I was doing.

473
00:21:36,720 --> 00:21:37,890
Well, you could have done it either way.

474
00:21:37,890 --> 00:21:39,560
But I think, you know -- this is way better.

475
00:21:39,560 --> 00:21:42,630
I think this is way. My way was way better.

476
00:21:42,630 --> 00:21:44,000
It's rare, but true.

477
00:21:44,000 --> 00:21:45,930
I'm kidding you.

478
00:21:45,930 --> 00:21:47,200
Hey, I'm kidding you, bro.

479
00:21:47,200 --> 00:21:48,100
Okay, I've had enough of you.

480
00:21:48,100 --> 00:21:49,770
Yeah, no kidding, right? Okay.

481
00:21:49,770 --> 00:21:51,240
Alright. That's rad.

482
00:21:51,240 --> 00:21:53,740
Good job. Thank you.

483
00:21:53,740 --> 00:21:55,210
We've already stretched the cabin,

484
00:21:55,210 --> 00:21:58,210
lowered the seats, and added more room for bigger wheels,

485
00:21:58,210 --> 00:22:01,050
and now howard's in charge of addressing the trunk,

486
00:22:01,050 --> 00:22:03,680
the wheel wells, the engine bay --

487
00:22:03,690 --> 00:22:04,880
pretty much the whole car.

488
00:22:04,890 --> 00:22:07,490
Basically, because of all the modifications we did,

489
00:22:07,490 --> 00:22:09,620
I'm working on closing the trunk area.

490
00:22:09,620 --> 00:22:11,160
This is the gas tank surround.

491
00:22:11,160 --> 00:22:12,830
The gas tank will drop down into here.

492
00:22:12,830 --> 00:22:15,430
We have these drop-down panels, and it all gets sealed.

493
00:22:15,430 --> 00:22:16,700
That way, you won't have exhaust fumes

494
00:22:16,700 --> 00:22:18,560
and stuff coming up into the car.

495
00:22:26,040 --> 00:22:28,070
dave: On this car, it's all about making sure

496
00:22:28,080 --> 00:22:29,480
that the surfaces are smooth

497
00:22:29,480 --> 00:22:31,710
and can be replicated with a great mold.

498
00:22:31,710 --> 00:22:34,050
That means we're using anything we need to --

499
00:22:34,050 --> 00:22:37,420
cardboard, bondo, fiberglass, steel, aluminum.

500
00:22:37,420 --> 00:22:38,920
You name it, we're using it.

501
00:22:38,920 --> 00:22:41,850
Heck, we might even get the 3-d printer going for this one.

502
00:22:47,460 --> 00:22:49,460
kevin: You know, ever since the beginning of time,

503
00:22:49,460 --> 00:22:51,730
chevrolet built these cars out of fiberglass.

504
00:22:51,730 --> 00:22:53,530
Corvettes were built from fiberglass

505
00:22:53,530 --> 00:22:56,600
because in the very first one, it was a performance car

506
00:22:56,600 --> 00:22:58,540
and they were looking to save weight.

507
00:22:58,540 --> 00:23:01,740
It's not my favorite thing or substrate to work with,

508
00:23:01,740 --> 00:23:03,040
but it has its advantages.

509
00:23:03,040 --> 00:23:05,440
It's light. It's pretty strong.

510
00:23:05,450 --> 00:23:07,380
I don't know if I'd want to get in a car accident.

511
00:23:07,380 --> 00:23:08,980
And howard loves it.

512
00:23:17,290 --> 00:23:19,530
dave: We've already completed a ton of design changes

513
00:23:19,530 --> 00:23:21,290
on this particular corvette.

514
00:23:23,600 --> 00:23:26,670
But we're not even close to being done yet.

515
00:23:26,670 --> 00:23:28,330
Greg is going to scan the entire car

516
00:23:28,340 --> 00:23:29,840
so we have digital information

517
00:23:29,840 --> 00:23:32,370
so that we can develop the trim around the doors,

518
00:23:32,370 --> 00:23:34,770
the windshield frame, headlights and taillights

519
00:23:34,780 --> 00:23:36,380
and some other parts.

520
00:23:42,650 --> 00:23:45,180
greg: Replicate where the headlights are going to be.

521
00:23:52,790 --> 00:23:54,760
hey, guys. How's the c-1 coming along? Good?

522
00:23:54,760 --> 00:23:56,230
Yeah, it's coming awesome.

523
00:23:56,230 --> 00:23:57,700
Greg's got it pretty much all scanned in,

524
00:23:57,700 --> 00:23:58,960
so we'll have the digital information.

525
00:23:58,970 --> 00:24:00,270
So we're ready to start moving on

526
00:24:00,270 --> 00:24:01,700
to molds to get some fiberglass bodies coming.

527
00:24:01,700 --> 00:24:02,900
Far out.

528
00:24:02,900 --> 00:24:04,600
So, I'm glad you brought that up, actually.

529
00:24:04,610 --> 00:24:06,170
Something I wanted to talk to you guys about.

530
00:24:06,170 --> 00:24:09,580
I have a couple of friends. Do you remember doug graf?

531
00:24:09,580 --> 00:24:10,910
Oh, yeah, from crc?

532
00:24:10,910 --> 00:24:13,250
You know, all corvettes were made out of fiberglass.

533
00:24:13,250 --> 00:24:16,520
But what makes a kindig-it design corvette better?

534
00:24:16,520 --> 00:24:17,820
I think I know where this is going.

535
00:24:19,690 --> 00:24:21,120
I think I'm going to have these bodies done

536
00:24:21,120 --> 00:24:22,520
out of carbon fiber.

537
00:24:22,520 --> 00:24:24,420
I don't know why you didn't do that in the first place.

538
00:24:24,430 --> 00:24:27,090
Well, I was thinking, you know, doing the press molds and stuff.

539
00:24:27,090 --> 00:24:29,700
But to be honest with you, I think by the time the cost

540
00:24:29,700 --> 00:24:33,170
is all factored in and that and the fact that carbon fiber

541
00:24:33,170 --> 00:24:37,070
is just that much cooler and it's lightweight, strong,

542
00:24:37,070 --> 00:24:38,600
and I think it's a hell of a sales point,

543
00:24:38,610 --> 00:24:41,270
I think we're going to do these things out of carbon fiber.

544
00:24:41,280 --> 00:24:43,010
That sounds like a lot more work,

545
00:24:43,010 --> 00:24:44,310
and we thought we were done.

546
00:24:44,310 --> 00:24:46,380
Big time.

547
00:24:46,380 --> 00:24:47,850
but you're all bad news.

548
00:24:47,850 --> 00:24:49,520
Wait until these guys see what I'm seeing.

549
00:24:49,520 --> 00:24:51,350
Guys. Fellas.

550
00:24:51,350 --> 00:24:55,860
It's our first kindig-it design full carbon-fiber turnkey car.

551
00:25:05,830 --> 00:25:10,040
Yeah, that's not what I'm seeing. Not even close.

552
00:25:10,040 --> 00:25:12,200
Okay, can you please talk them into doing the molds?

553
00:25:12,210 --> 00:25:14,110
I don't think it's that hard. Really?

554
00:25:14,110 --> 00:25:15,570
"I don't think it's that hard."

555
00:25:15,580 --> 00:25:17,110
I want to move through this project.

556
00:25:17,110 --> 00:25:18,940
I want to keep going.

557
00:25:18,950 --> 00:25:20,650
I was just about to go on vacation.

558
00:25:20,650 --> 00:25:21,710
Don't do that. Me, too.

559
00:25:21,720 --> 00:25:23,120
Don't either one of you do that.

560
00:25:23,120 --> 00:25:24,680
Let's picture this. Let's picture this.

561
00:25:24,690 --> 00:25:26,490
A white sandy beach

562
00:25:26,490 --> 00:25:28,720
with sea turtles. And a carbon fiber corvette.

563
00:25:28,720 --> 00:25:30,360
No, no, there's no corvettes there

564
00:25:30,360 --> 00:25:31,990
'cause there's no work there. It's the beach.

565
00:25:31,990 --> 00:25:33,930
With the boats. With the boats.

566
00:25:33,930 --> 00:25:35,590
Is there room on that boat for me?

567
00:25:35,600 --> 00:25:37,230
There's a lady that comes up in a bikini

568
00:25:37,230 --> 00:25:40,130
and brings me piña coladas all day long.

569
00:25:44,140 --> 00:25:45,570
that's really hard to beat.

570
00:25:45,570 --> 00:25:48,010
But I am really excited about these bodies, though, guys.

571
00:25:48,010 --> 00:25:49,540
We're going to go. We need to go to the internet.

572
00:25:49,540 --> 00:25:52,880
We're going to get plane tickets to bora bora.

573
00:25:52,880 --> 00:25:55,410
They're making molds in bora bora?

574
00:25:55,420 --> 00:25:56,620
You're not invited.

575
00:25:56,620 --> 00:25:58,080
Doug and austin will be here next week.

576
00:25:58,090 --> 00:26:00,520
-Bye. -Uh-huh.

577
00:26:00,520 --> 00:26:02,590
Put the bora bora up your butt.

578
00:26:04,960 --> 00:26:06,960
Regardless of what the guys in the shop think,

579
00:26:06,960 --> 00:26:09,700
carbon fiber is definitely going to put us to another level,

580
00:26:09,700 --> 00:26:11,900
and here comes the experts to show us how.

581
00:26:11,900 --> 00:26:12,930
Doug, here we go.

582
00:26:12,930 --> 00:26:14,100
Austin, what do you think?

583
00:26:14,100 --> 00:26:16,600
Austin: Beautiful. Absolutely gorgeous.

584
00:26:16,600 --> 00:26:18,740
We're here with doug in austin, and doug graf

585
00:26:18,740 --> 00:26:20,710
is the owner of crc.

586
00:26:20,710 --> 00:26:22,740
I think we've got you guys a pretty good plug car,

587
00:26:22,740 --> 00:26:25,010
but I'm glad you guys came down here to look at it.

588
00:26:25,010 --> 00:26:26,980
Doug graf and his right hand man austin are here

589
00:26:26,980 --> 00:26:30,480
to show us exactly how to make the perfect carbon fiber mold

590
00:26:30,480 --> 00:26:32,280
for the perfect carbon fiber parts.

591
00:26:32,290 --> 00:26:34,050
These guys have been doing it for a long time,

592
00:26:34,060 --> 00:26:35,520
so I'm really interested to find out

593
00:26:35,520 --> 00:26:37,120
how it's done and do it right.

594
00:26:37,120 --> 00:26:38,460
Austin: Our goal is to come in here

595
00:26:38,460 --> 00:26:41,390
and help you to fashion the splits on the molds.

596
00:26:41,400 --> 00:26:44,530
I know you want to make a one-piece mold for this body,

597
00:26:44,530 --> 00:26:45,630
which will be incredible.

598
00:26:45,630 --> 00:26:47,200
Little bit of an extra challenge,

599
00:26:47,200 --> 00:26:48,630
but it's that extra distance

600
00:26:48,640 --> 00:26:50,270
that you usually go on your cars.

601
00:26:50,270 --> 00:26:51,640
We're going to love working with you.

602
00:26:51,640 --> 00:26:53,910
Yeah. Well, and I think we're going to love the fact

603
00:26:53,910 --> 00:26:55,980
that the car is not another fiberglass...

604
00:26:55,980 --> 00:26:58,640
Yeah. ...Corvette. It's carbon fiber.

605
00:26:58,650 --> 00:27:00,810
For those of you who are corvette aficionados

606
00:27:00,820 --> 00:27:02,210
and purists,

607
00:27:02,220 --> 00:27:03,450
you might want to turn your head.

608
00:27:03,450 --> 00:27:05,880
My intention of this car is to not necessarily have

609
00:27:05,890 --> 00:27:07,890
any carbon fiber clear coated.

610
00:27:07,890 --> 00:27:09,050
So, let's talk about the mold.

611
00:27:09,060 --> 00:27:11,090
Basically, everything on this car

612
00:27:11,090 --> 00:27:13,460
has to release almost like a stack of dixie cups.

613
00:27:13,460 --> 00:27:15,790
You want to be able to pull the cups off,

614
00:27:15,800 --> 00:27:16,800
and you'll have your piece,

615
00:27:16,800 --> 00:27:18,200
which would be the next cup down.

616
00:27:18,200 --> 00:27:20,100
So what is the first thing that we need

617
00:27:20,100 --> 00:27:21,830
to do on our mold making?

618
00:27:21,840 --> 00:27:23,040
We're going to need to start

619
00:27:23,040 --> 00:27:25,640
finding our partition lines for the mold.

620
00:27:25,640 --> 00:27:28,340
Obviously, we can't make this in one large piece.

621
00:27:28,340 --> 00:27:30,110
You'll never get the part out of the mold.

622
00:27:30,110 --> 00:27:31,410
We're going to need to divide this up

623
00:27:31,410 --> 00:27:33,650
into a number of sections.

624
00:27:33,650 --> 00:27:35,950
The car will come out in one piece,

625
00:27:35,950 --> 00:27:38,280
but the mold will have to be separated.

626
00:27:38,290 --> 00:27:41,150
When we make our parts, we need a vacuum flange.

627
00:27:41,160 --> 00:27:44,290
We need an outside-the-part perimeter,

628
00:27:44,290 --> 00:27:48,490
and then we adhere a solid bag, put a vacuum port on it,

629
00:27:48,500 --> 00:27:52,200
take all the air out of it, which creates about 12 pounds

630
00:27:52,200 --> 00:27:55,270
per square inch of vacuum pressure on those parts.

631
00:27:55,270 --> 00:27:57,470
That's why we get such an incredible part,

632
00:27:57,470 --> 00:27:58,740
and it's only seventy-thousandths

633
00:27:58,740 --> 00:27:59,570
of an inch thick.

634
00:27:59,570 --> 00:28:00,870
That's awesome.

635
00:28:00,880 --> 00:28:02,110
Building a carbon fiber mold

636
00:28:02,110 --> 00:28:03,640
takes special attention to detail

637
00:28:03,640 --> 00:28:05,310
to make sure all of the parts line up.

638
00:28:05,310 --> 00:28:06,610
Austin: Yeah, it's just going to --

639
00:28:06,610 --> 00:28:08,950
I think it'll just go like clockwork.

640
00:28:08,950 --> 00:28:11,150
I can't wait. Well, we're ready to get started immediately.

641
00:28:11,150 --> 00:28:12,380
So, let's pull some molds.

642
00:28:12,390 --> 00:28:14,190
Sounds good. I'm ready. Awesome.

643
00:28:14,190 --> 00:28:15,490
Looking very forward to getting it done.

644
00:28:15,490 --> 00:28:17,320
Awesome. Thanks again. Welcome aboard, sir.

645
00:28:17,320 --> 00:28:18,720
Thank you. Thank you.

646
00:28:18,730 --> 00:28:21,060
Before we can build the molds, there's still one thing

647
00:28:21,060 --> 00:28:22,760
that we have to do, no matter what,

648
00:28:22,760 --> 00:28:24,430
even if I don't want to do it.

649
00:28:41,120 --> 00:28:42,720
dave: We just met with doug and austin,

650
00:28:42,720 --> 00:28:45,050
the professionals that do this carbon fiber stuff,

651
00:28:45,050 --> 00:28:47,020
and we're ready to start pulling molds.

652
00:28:55,530 --> 00:28:58,200
really, the car's charm is to have these cool little fins

653
00:28:58,200 --> 00:29:00,400
on the rear quarter panels, and to be honest with you,

654
00:29:00,400 --> 00:29:03,740
I'm a little sad to see them being chopped off.

655
00:29:15,480 --> 00:29:17,320
it sucks in the moment, but it's important

656
00:29:17,320 --> 00:29:19,080
that the car comes out of the mold.

657
00:29:23,890 --> 00:29:26,790
I'd like a moment of silence for the fins.

658
00:29:31,570 --> 00:29:32,530
that'll do.

659
00:29:32,530 --> 00:29:33,870
Every last one of these panels

660
00:29:33,870 --> 00:29:36,370
has been dialed in and is flawless.

661
00:29:36,370 --> 00:29:38,600
Now it's time to start pulling some molds.

662
00:29:38,610 --> 00:29:41,240
The smaller molds, such as the inside and outside of the doors,

663
00:29:41,240 --> 00:29:43,980
the trunk, and the hood, they're going to be a lot easier to do.

664
00:29:43,980 --> 00:29:45,380
So, we're going to go out and start on those

665
00:29:45,380 --> 00:29:47,850
and get a hang of how to build a proper mold.

666
00:29:47,850 --> 00:29:49,780
This is all tooling mold fiberglass,

667
00:29:49,780 --> 00:29:51,850
so that can actually take higher temps.

668
00:29:51,850 --> 00:29:53,550
One of the big things that we need to start with, though,

669
00:29:53,550 --> 00:29:55,850
is this black epoxy resin.

670
00:29:55,860 --> 00:29:58,520
It's official name is pt1540.

671
00:30:00,490 --> 00:30:02,030
Pain in the ass.

672
00:30:04,170 --> 00:30:05,330
Once we get this pain in the ass --

673
00:30:05,330 --> 00:30:07,870
I'm sorry -- black epoxy resin down,

674
00:30:07,870 --> 00:30:09,640
then it's time for jason to figure out a pattern

675
00:30:09,640 --> 00:30:11,870
to put all of the fiberglass layers down.

676
00:30:17,110 --> 00:30:18,710
jason: So, we got a ton of molds to make.

677
00:30:18,710 --> 00:30:19,910
We've made a few of them,

678
00:30:19,910 --> 00:30:22,150
but we're using this fiberglass cloth.

679
00:30:22,150 --> 00:30:24,420
It's a little bit better for what we're doing to build

680
00:30:24,420 --> 00:30:26,250
the molds 'cause we want the molds to be super strong

681
00:30:26,250 --> 00:30:27,450
and structural.

682
00:30:27,450 --> 00:30:29,220
We want to do this concept car justice,

683
00:30:29,220 --> 00:30:30,960
and that means we got to make the perfect mold

684
00:30:30,960 --> 00:30:32,590
and keep them very structural.

685
00:30:32,590 --> 00:30:35,230
We've got the deck lid on the outside done.

686
00:30:35,230 --> 00:30:37,130
Now we have to do the bottom side.

687
00:30:37,130 --> 00:30:39,730
So we've got the structure for the mold in place.

688
00:30:39,730 --> 00:30:42,840
Now, all we're going to do is glue all of the structure

689
00:30:42,840 --> 00:30:44,340
together to hold it where we want,

690
00:30:44,340 --> 00:30:46,910
and then we should be able to pop the mold soon as that dries.

691
00:30:46,910 --> 00:30:49,810
You can tell how much fun it is because the first day

692
00:30:49,810 --> 00:30:51,810
when we started this, everybody was all gung-ho.

693
00:30:51,810 --> 00:30:54,310
We had how many people over here? Like...

694
00:30:54,320 --> 00:30:56,550
Ten people all excited, wanted to help,

695
00:30:56,550 --> 00:30:57,650
and now it's me and maddie.

696
00:31:04,060 --> 00:31:07,330
takes forever. I mean, if you did one part steady,

697
00:31:07,330 --> 00:31:10,030
it'd probably take two or three days

698
00:31:10,030 --> 00:31:12,160
per part on the car.

699
00:31:12,170 --> 00:31:16,240
It'll be fun when the project's done, just not right now.

700
00:31:23,210 --> 00:31:24,840
the molds are now completely dry

701
00:31:24,850 --> 00:31:26,410
and ready for a b-stage cure,

702
00:31:26,410 --> 00:31:29,250
but first, we've got to try and get the part out of them.

703
00:31:34,190 --> 00:31:36,590
Popping the molds is my favorite part of the whole process

704
00:31:36,590 --> 00:31:39,560
because everything else is just wet and sticky and messy,

705
00:31:39,560 --> 00:31:42,130
but then popping that piece off, hearing it crack loose,

706
00:31:42,130 --> 00:31:45,800
it's just so satisfying to see an awesome, perfect lay-up.

707
00:31:45,800 --> 00:31:47,600
Some parts are really easy to pop loose

708
00:31:47,600 --> 00:31:49,100
because they're not very contoured.

709
00:31:49,100 --> 00:31:50,940
Other ones are a little bit tricky.

710
00:31:53,670 --> 00:31:56,170
When these molds don't pop out the way they're supposed to,

711
00:31:56,180 --> 00:31:57,880
it gets really stressful.

712
00:32:01,280 --> 00:32:03,350
The idea is to not damage any of the molds.

713
00:32:03,350 --> 00:32:08,150
I mean, of course, you may have a small chip or a crack.

714
00:32:08,160 --> 00:32:11,360
If we find any major problems, that could be bad.

715
00:32:11,360 --> 00:32:14,260
This would put us right back to step one of mold building.

716
00:32:14,260 --> 00:32:16,190
Sucks to do it the first time.

717
00:32:16,200 --> 00:32:18,700
It would really suck to do it a second time.

718
00:32:21,600 --> 00:32:22,530
Man: Damn!

719
00:32:27,110 --> 00:32:29,740
Greg: I finished printing the last pieces

720
00:32:29,740 --> 00:32:31,440
of my windshield frame

721
00:32:31,450 --> 00:32:34,280
that I've been designing for the '53 corvette.

722
00:32:34,280 --> 00:32:36,450
The pieces in the printer are actually super hot.

723
00:32:36,450 --> 00:32:38,250
So when I pull them out, I need the gloves

724
00:32:38,250 --> 00:32:39,690
so I don't burn my hands.

725
00:32:39,690 --> 00:32:41,620
This thing's basically an oven.

726
00:32:43,790 --> 00:32:46,290
I had to print them of crazy standing up like that

727
00:32:46,290 --> 00:32:47,560
just because they're so big.

728
00:32:47,560 --> 00:32:48,930
The windshield frame for the car

729
00:32:48,930 --> 00:32:51,130
is, you know, the width of the car

730
00:32:51,130 --> 00:32:53,570
and then it's about a foot tall.

731
00:32:53,570 --> 00:32:57,700
So, what I did was I chopped it into sections in the computer

732
00:32:57,710 --> 00:32:59,340
and then once they're all cleaned up,

733
00:32:59,340 --> 00:33:01,670
I can glue them all together and then we can get an idea

734
00:33:01,680 --> 00:33:03,640
of what the windshield frame will look like.

735
00:33:03,640 --> 00:33:07,150
The final piece is going to be cast out of bronze

736
00:33:07,150 --> 00:33:08,810
and then it'll be chrome plated.

737
00:33:08,820 --> 00:33:11,750
I showed dave in the computer what it looked like

738
00:33:11,750 --> 00:33:13,290
and he likes the way it's going.

739
00:33:13,290 --> 00:33:15,820
But having it in real life on the car is just --

740
00:33:15,820 --> 00:33:17,260
it's invaluable.

741
00:33:17,260 --> 00:33:19,890
I need to break out the support materials.

742
00:33:19,890 --> 00:33:21,230
I got these things all cleaned up,

743
00:33:21,230 --> 00:33:22,530
and the way they go together,

744
00:33:22,530 --> 00:33:24,900
you can see right here, I cut these little pins

745
00:33:24,900 --> 00:33:26,100
and put them in and glued them in.

746
00:33:26,100 --> 00:33:27,200
With this last one,

747
00:33:27,200 --> 00:33:28,800
we got to do both sides at the same time,

748
00:33:28,800 --> 00:33:31,840
so I'm having eric help me with this last little bit.

749
00:33:35,110 --> 00:33:36,610
Okay. I'm started.

750
00:33:36,610 --> 00:33:37,940
This stuff set so quick.

751
00:33:37,950 --> 00:33:40,080
Just makes me so anxious every time

752
00:33:40,080 --> 00:33:41,410
I use this kind of glue.

753
00:33:41,420 --> 00:33:43,620
This is looking really good, and it all fit together

754
00:33:43,620 --> 00:33:44,620
really nicely.

755
00:33:44,620 --> 00:33:46,320
It seems really strong.

756
00:33:46,320 --> 00:33:48,020
I think this worked out really well.

757
00:33:53,190 --> 00:33:55,560
Jason: You got the deck lid on the outside done.

758
00:33:55,560 --> 00:33:57,660
Now we have to do the bottom side.

759
00:33:57,660 --> 00:34:00,130
When these molds don't pop out the way they're supposed to,

760
00:34:00,130 --> 00:34:01,870
it gets really stressful.

761
00:34:04,670 --> 00:34:06,510
Some parts are really easy to pop loose

762
00:34:06,510 --> 00:34:07,970
because they're not very contoured.

763
00:34:07,980 --> 00:34:11,510
Other ones are a little bit tricky.

764
00:34:11,510 --> 00:34:14,180
There it goes.

765
00:34:14,180 --> 00:34:16,780
Pulled the old boot out to make the molds.

766
00:34:16,780 --> 00:34:19,280
Now we have the inner structure mold

767
00:34:19,290 --> 00:34:21,120
so we can lay the carbon down.

768
00:34:21,120 --> 00:34:23,820
It looks awesome. Just got to clean this up.

769
00:34:26,590 --> 00:34:29,190
We've completed the plug for our concept style car

770
00:34:29,200 --> 00:34:30,960
after months and months of work,

771
00:34:30,960 --> 00:34:33,130
but the plug is not the final part of the car.

772
00:34:33,130 --> 00:34:36,500
This is just the plug that will create the perfect molds

773
00:34:36,500 --> 00:34:38,240
off the perfect plug.

774
00:34:38,240 --> 00:34:40,670
And so far, the molds are looking pretty good.

775
00:34:43,640 --> 00:34:45,140
We're getting really good at making molds

776
00:34:45,150 --> 00:34:46,550
for the smaller pieces,

777
00:34:46,550 --> 00:34:51,180
but the big body, itt's coming up next.

778
00:34:51,190 --> 00:34:53,020
Jason: We're starting to put the body mold separators

779
00:34:53,020 --> 00:34:54,420
on the front of the car and the rear.

780
00:34:54,420 --> 00:34:57,960
If we can build four or five, six different molds,

781
00:34:57,960 --> 00:35:01,260
but then when we pull them off, we have one solid piece

782
00:35:01,260 --> 00:35:03,860
so we can not have any seams or anything on it,

783
00:35:03,860 --> 00:35:05,660
so we're going to split it down the center

784
00:35:05,670 --> 00:35:07,130
and then down the top of each fender

785
00:35:07,130 --> 00:35:09,330
so we can start glassing them in

786
00:35:09,340 --> 00:35:11,400
and getting them ready to lay up,

787
00:35:11,410 --> 00:35:13,040
top it all off at one time.

788
00:35:13,040 --> 00:35:14,310
That's when it'll all be worth it.

789
00:35:14,310 --> 00:35:18,380
But until then, fiberglass blows.

790
00:35:18,380 --> 00:35:21,650
Maddie: I'm filling in all the cracks with clay

791
00:35:21,650 --> 00:35:25,380
so that when we put the hardware and fiberglass on,

792
00:35:25,390 --> 00:35:26,650
it won't leak through.

793
00:35:26,650 --> 00:35:29,620
Then we'll good edges for each side of the mold.

794
00:35:29,620 --> 00:35:31,890
Jason: Maddie's really good at the clay stuff.

795
00:35:31,890 --> 00:35:34,660
She gets it really smooth. So we can seam all the cracks.

796
00:35:34,660 --> 00:35:36,360
Definitely important to get every step right.

797
00:35:36,360 --> 00:35:40,130
If you forget to seal off a piece with clay,

798
00:35:40,130 --> 00:35:41,930
then you have an extra extension on the mold

799
00:35:41,940 --> 00:35:43,840
that you then have in every single piece.

800
00:35:43,840 --> 00:35:46,070
If you forget the wax, you ain't gonna pop the mold.

801
00:35:46,070 --> 00:35:47,170
If you forget the gel coat,

802
00:35:47,170 --> 00:35:49,410
it's not going to pop out. Great.

803
00:35:49,410 --> 00:35:52,010
Definitely don't want to miss any steps.

804
00:35:52,010 --> 00:35:53,750
It's not just one simple part you can redo.

805
00:35:53,750 --> 00:35:55,780
It's the entire skin and body

806
00:35:55,780 --> 00:35:57,750
and structure interior of the car.

807
00:36:09,730 --> 00:36:11,000
we're ready to start laying the glass

808
00:36:11,000 --> 00:36:12,760
on the bottom side of the roll pan.

809
00:36:12,770 --> 00:36:14,930
This is going to be upside down.

810
00:36:14,940 --> 00:36:16,330
Gonna have one person on the floor,

811
00:36:16,340 --> 00:36:18,740
which is me.

812
00:36:18,740 --> 00:36:19,870
I lost the bet.

813
00:36:19,870 --> 00:36:21,540
Yeah, I don't have to be under the car today.

814
00:36:24,040 --> 00:36:25,240
maddie's going to hand them down to me,

815
00:36:25,250 --> 00:36:27,980
and then we'll just put them on upside down

816
00:36:27,980 --> 00:36:32,920
and enjoy the potential rainfall of resin drips.

817
00:36:32,920 --> 00:36:34,750
It's definitely going to be running down my hands.

818
00:36:34,760 --> 00:36:37,190
So, I'm just trying to minimize the inevitable.

819
00:36:39,030 --> 00:36:40,430
Yep. Ready to roll.

820
00:36:52,310 --> 00:36:53,410
we're almost there.

821
00:36:53,410 --> 00:36:55,610
I see the light at the end of the tunnel.

822
00:36:57,740 --> 00:36:59,950
The crew is making great progress on these molds

823
00:36:59,950 --> 00:37:01,850
for the c-1 carbon fiber corvettes.

824
00:37:01,850 --> 00:37:05,980
We've already got the top and the front and rear made,

825
00:37:05,990 --> 00:37:07,990
but now it's time to tackle the sides.

826
00:37:07,990 --> 00:37:10,220
So, the car's coming along really well.

827
00:37:10,220 --> 00:37:13,260
This is by far -- by far, far --

828
00:37:13,260 --> 00:37:15,660
the biggest piece of fiberglass I've ever made.

829
00:37:15,660 --> 00:37:18,260
We got the entire top half of the car in glass.

830
00:37:18,270 --> 00:37:19,730
So, what we're doing now

831
00:37:19,730 --> 00:37:21,030
is maddie and I are chasing the sides.

832
00:37:21,030 --> 00:37:22,500
We're getting them prepped.

833
00:37:22,500 --> 00:37:25,000
Want to get them laid up so we can get the rest of the mold,

834
00:37:25,010 --> 00:37:26,100
then we can pop it apart,

835
00:37:26,110 --> 00:37:27,410
take everything off.

836
00:37:27,410 --> 00:37:29,310
So, right now, we're doing the doors.

837
00:37:29,310 --> 00:37:30,510
We've got one side done.

838
00:37:30,510 --> 00:37:32,640
I was able to crawl in there and do that side.

839
00:37:32,650 --> 00:37:34,150
Maddie's got to do this side

840
00:37:34,150 --> 00:37:36,410
because I'm not skinny enough to get out the back of the car.

841
00:37:36,420 --> 00:37:39,780
So, she gets to be the one who gets locked inside the car.

842
00:37:39,790 --> 00:37:43,290
So, we're going to put on this side door flange

843
00:37:43,290 --> 00:37:45,590
to lay up the car, drill it in place,

844
00:37:45,590 --> 00:37:47,760
and then start planing it

845
00:37:47,760 --> 00:37:48,830
and getting ready to lay up the glass

846
00:37:48,830 --> 00:37:50,100
on the sides of the car.

847
00:37:50,100 --> 00:37:51,200
Should go really well.

848
00:37:51,200 --> 00:37:54,000
Just a little claustrophobia going on.

849
00:37:55,970 --> 00:37:57,670
I don't think so, but I guess we'll see.

850
00:37:57,670 --> 00:38:02,570
The reason we're putting these door panel pieces on

851
00:38:02,580 --> 00:38:04,280
is because we want to make a one-piece mold

852
00:38:04,280 --> 00:38:05,410
is what we're after.

853
00:38:05,410 --> 00:38:07,850
The sides of the car half a lower rocker,

854
00:38:07,850 --> 00:38:09,750
but because it's got the rocker,

855
00:38:09,750 --> 00:38:12,080
we don't want to have one piece without a center section.

856
00:38:12,090 --> 00:38:14,790
It has the potential to bend or bow

857
00:38:14,790 --> 00:38:16,220
and crack in the middle.

858
00:38:16,220 --> 00:38:18,160
And since we're doing a one piece mold,

859
00:38:18,160 --> 00:38:19,660
we're going to use this and we're actually going to

860
00:38:19,660 --> 00:38:21,190
lay glass in and on it

861
00:38:21,190 --> 00:38:23,660
strictly as a structural support.

862
00:38:23,660 --> 00:38:24,700
'cause everybody does pieces,

863
00:38:24,700 --> 00:38:27,100
but we want it one solid piece

864
00:38:27,100 --> 00:38:28,970
when it comes out as carbon fiber.

865
00:38:28,970 --> 00:38:31,800
I think this is going to be easier said than done.

866
00:38:31,810 --> 00:38:33,200
I'll just leave it up to jason.

867
00:38:33,210 --> 00:38:35,970
If you kick your feet in with the front

868
00:38:35,980 --> 00:38:37,540
at the very bottom of the panel --

869
00:38:37,540 --> 00:38:38,540
just push it in hard.

870
00:38:38,550 --> 00:38:39,840
Don't worry about bending the metal.

871
00:38:39,850 --> 00:38:43,050
If you can put it at the very bottom of the edge.

872
00:38:43,050 --> 00:38:44,920
There's too much wax. Give me a second.

873
00:38:44,920 --> 00:38:47,720
-There's too much what? -Wax. I just keep moving.

874
00:38:47,720 --> 00:38:49,290
Yeah, it's super slippery in there.

875
00:38:52,130 --> 00:38:54,030
can you pull it up more on the front?

876
00:38:54,030 --> 00:38:55,430
Uh...

877
00:38:55,430 --> 00:38:56,430
Try that.

878
00:38:56,430 --> 00:38:57,630
Probably as close as we can get.

879
00:38:57,630 --> 00:38:59,630
When you drill, just drill, like,

880
00:38:59,630 --> 00:39:02,400
just barely above the bottom of the sheet metal.

881
00:39:05,810 --> 00:39:08,040
That's not holding it in enough.

882
00:39:08,040 --> 00:39:10,280
I can't hear a word she's saying.

883
00:39:10,280 --> 00:39:11,910
Sounds like charlie brown's teacher.

884
00:39:11,910 --> 00:39:14,650
Wah-wah-wah- wah-wah-wah.

885
00:39:14,650 --> 00:39:17,080
okay, try it.

886
00:39:17,080 --> 00:39:19,150
There you go.

887
00:39:19,150 --> 00:39:20,320
Yeah, that looks good.

888
00:39:20,320 --> 00:39:22,720
Well, my job's over 'cause that's screwed in place.

889
00:39:22,720 --> 00:39:24,020
I could probably go to lunch and come back

890
00:39:24,020 --> 00:39:25,290
and she'd never even know.

891
00:39:25,290 --> 00:39:26,420
I wouldn't really do that.

892
00:39:26,430 --> 00:39:28,060
There's still a lot more I can help out with.

893
00:39:28,060 --> 00:39:29,860
I'm going to send the welder in.

894
00:39:29,860 --> 00:39:31,400
Maddie: Okay. Let's just put one

895
00:39:31,400 --> 00:39:32,800
right in the center since this is the one

896
00:39:32,800 --> 00:39:34,500
we got crawling and grind out.

897
00:39:34,500 --> 00:39:35,730
Okay.

898
00:39:41,680 --> 00:39:43,210
perfect. Okay.

899
00:39:43,210 --> 00:39:44,710
I think that's good.

900
00:39:44,710 --> 00:39:45,740
There was some stuff.

901
00:39:45,750 --> 00:39:47,850
Okay, come on out.

902
00:39:47,850 --> 00:39:50,380
Oh, that knee's stuck.

903
00:39:54,990 --> 00:39:58,260
We are making the molds of our concept styled kindig vettes.

904
00:39:58,260 --> 00:39:59,590
Jason: Right now, we're doing the doors.

905
00:39:59,590 --> 00:40:00,830
We got one side done.

906
00:40:00,830 --> 00:40:02,790
I was able to crawl in there and do that side.

907
00:40:02,800 --> 00:40:03,900
Maddie's got to do this side

908
00:40:03,900 --> 00:40:05,360
because I'm not skinny enough

909
00:40:05,370 --> 00:40:06,500
to get out the back of the car.

910
00:40:08,240 --> 00:40:10,070
I don't think so, but I guess we'll see.

911
00:40:10,070 --> 00:40:11,570
Not yet.

912
00:40:17,410 --> 00:40:20,310
jason: Perfect. Okay, come on out.

913
00:40:20,310 --> 00:40:22,580
Oh, that knee is stuck.

914
00:40:22,580 --> 00:40:24,150
Oh.

915
00:40:24,150 --> 00:40:25,780
Awesome. That worked out great.

916
00:40:25,790 --> 00:40:27,190
Ugh.

917
00:40:27,190 --> 00:40:29,690
Now we know that maddie can get in and out of this car,

918
00:40:29,690 --> 00:40:32,460
I got some more bad news for her after we finish the sidewalls.

919
00:40:32,460 --> 00:40:33,530
You know, you got to do it one more time

920
00:40:33,530 --> 00:40:35,830
when we take it out. Wonderful.

921
00:40:35,830 --> 00:40:37,330
Funnest thing all day.

922
00:40:39,400 --> 00:40:42,600
This is just a filler material to speed up the process.

923
00:40:42,600 --> 00:40:45,570
Well, let's start cleaning up, cleaning it.

924
00:40:45,570 --> 00:40:47,370
And we fill in a little bit of gap

925
00:40:47,370 --> 00:40:49,110
that we have with the clay

926
00:40:49,110 --> 00:40:51,610
so we get a perfect, nice, flat mold.

927
00:40:51,610 --> 00:40:54,180
After getting the door section ready for the vacuum bags,

928
00:40:54,180 --> 00:40:55,610
maddie's going to put in a flange

929
00:40:55,620 --> 00:40:57,050
around the wheel well opening

930
00:40:57,050 --> 00:40:59,250
so they have somewhere to tape off the bags.

931
00:40:59,250 --> 00:41:02,250
Next, it's all hands on deck for the side molds.

932
00:41:02,260 --> 00:41:03,760
Yeah, I ain't doing this alone.

933
00:41:03,760 --> 00:41:06,420
I'm bringing them down with me.

934
00:41:06,430 --> 00:41:07,760
We want to make sure that the sides

935
00:41:07,760 --> 00:41:09,460
are structured up enough to make sure

936
00:41:09,460 --> 00:41:11,700
that they can withstand the vacuum pressure

937
00:41:11,700 --> 00:41:12,730
of a vacuum mold.

938
00:41:12,730 --> 00:41:14,400
The mandatory amount of fiberglass

939
00:41:14,400 --> 00:41:16,030
to make sure that these are solid

940
00:41:16,040 --> 00:41:19,000
and not going to twist or move is very important.

941
00:41:19,010 --> 00:41:22,670
-This is layer two of 11. -This is layer one.

942
00:41:22,680 --> 00:41:24,440
Well, you guys are behind us. Trying to make you look good.

943
00:41:25,550 --> 00:41:27,250
man: Hey, coming to help?

944
00:41:27,250 --> 00:41:28,450
No.

945
00:41:30,550 --> 00:41:35,650
After this square, about 750,000 more squares.

946
00:41:35,660 --> 00:41:37,990
Dave: The idea behind doing smaller pieces of fiberglass

947
00:41:37,990 --> 00:41:39,420
on this big mold

948
00:41:39,430 --> 00:41:41,430
is so that it's easier to handle and manage,

949
00:41:41,430 --> 00:41:43,700
and of course, by crosshatching going straight

950
00:41:43,700 --> 00:41:48,330
and then 45 really adds a lot of strength to it.

951
00:41:48,340 --> 00:41:50,500
A few thousand squares of fiberglass later,

952
00:41:50,500 --> 00:41:51,900
we're ready for the backer board.

953
00:41:56,580 --> 00:41:58,040
This is going to add structure

954
00:41:58,040 --> 00:42:00,350
and make sure that the mold does not twist

955
00:42:00,350 --> 00:42:04,650
and it's able to be set upside down on a flat surface.

956
00:42:04,650 --> 00:42:06,580
After months and months of work,

957
00:42:06,590 --> 00:42:08,890
this thing is finally ready. Let's see how it looks.

958
00:42:08,890 --> 00:42:11,560
It's popping day. We're gonna pop the molds.

959
00:42:11,560 --> 00:42:13,530
Super excited, super nervous.

960
00:42:13,530 --> 00:42:14,960
Should turn out really good, though.

961
00:42:14,960 --> 00:42:16,930
Maddie jumped back in the car.

962
00:42:16,930 --> 00:42:17,960
Maddie: Okay.

963
00:42:17,960 --> 00:42:19,260
I'm gonna hang out here.

964
00:42:19,270 --> 00:42:21,670
Until she gets a couple of the metal backer boards

965
00:42:21,670 --> 00:42:23,070
that we put in that are taken off

966
00:42:23,070 --> 00:42:24,870
so we can pop the sides off.

967
00:42:30,240 --> 00:42:32,210
Check out our first piece.

968
00:42:34,280 --> 00:42:36,210
Whew.

969
00:42:38,350 --> 00:42:41,090
Hopefully it comes off easy, in one piece, and looks good

970
00:42:41,090 --> 00:42:42,720
because I don't want to redo it.

971
00:42:45,190 --> 00:42:46,260
Oh, tough guy's here.

972
00:42:46,260 --> 00:42:47,530
If things don't go smoothly,

973
00:42:47,530 --> 00:42:49,090
I'm gonna be really upset.

974
00:42:57,740 --> 00:42:59,840
there it goes.

975
00:42:59,840 --> 00:43:01,410
Yeah, you can see it. It's twisting right there.

976
00:43:01,410 --> 00:43:03,270
Pretty sure it's 'cause these lights.

977
00:43:05,880 --> 00:43:07,880
It looks like we have a little bit of a trap

978
00:43:07,880 --> 00:43:09,610
between the wheel well and the headlight,

979
00:43:09,620 --> 00:43:11,380
and we need to try and free this

980
00:43:11,380 --> 00:43:14,390
or break it loose without breaking the mold.

981
00:43:17,560 --> 00:43:19,620
yeah.

982
00:43:19,630 --> 00:43:20,830
Just don't pull too hard.

983
00:43:20,830 --> 00:43:22,730
This entire process has been very tedious

984
00:43:22,730 --> 00:43:24,130
on me and my crew,

985
00:43:24,130 --> 00:43:28,730
but this last part is going to push us over the edge.

986
00:43:28,740 --> 00:43:31,840
Whoa!

987
00:43:31,840 --> 00:43:33,270
Man: It's not budging.

987
00:43:34,305 --> 00:44:34,917