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Front end in primer and checking the bumper fit.. still some work to do to get a good panel gap.

Rear end has been welded together ready for filling & smoothing. The time for taking moulds is getting ever closer!

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Update on the sanding progress.. LOTS OF IT!

2nd coat of filler on the bonnet & wings.. 3rd coat of pattern coat on the bumper. Hopefully coat 4 will be the last, then I can add gloss and begin fine sanding & polishing.

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Lots of sanding..

First layer of pattern coat on and smoothed. 2nd layer is hardening overnight. Lots more sanding to go! O_o

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Front bumper pattern..

Finished sanding the foam down to the basic shape, then gave it a skim of filler. Lots more sanding to do..

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Building the front bumper pattern.. most motorsport jigsaw ever!

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I’ll just leave this here..

I’ll just leave this here..

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Then today I chopped up the rear half of the bodywork, with the intention of keeping only the quarter panels - everything else went in the bin. 

Once I had those, I did a little Cardboard Aided Design to tidy up the roof joint above the doors, then dressed it all smooth. 

Finally I tacked on the bits I’d chopped off the bottom.. wish I’d never cut them there, to be honest, but plans change!

You might guess how the rear bodywork will go together.. it’ll be a removable clam made up of 5 parts bonded together: quarter panels, roof panel, tailgate, and bumper / valence. I’ll get them all done in metal first, then take moulds of everything to make the composite parts.

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Yesterday - I picked up a non-sunroof skin ages ago, so got rounf to trimming the skin from the rest of the bracing etc. As with all the bodywork, I’ll be using the metal panels only for mould making. 

Once that was done, I cut off the sunroof skin from my shell.

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I spent last week at my favourite place, so figured I’d leave my mark.

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My resto GTI has kindly donated a door, so I’ve got the other side finished now, and the sill exhaust tunnels are now tacked on. (I did both sides to make the chassis symmetrical.. it’d be weird otherwise)

Front panel has been put back on the jig, ready to start getting the front bodywork together.

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Trimmed bodywork is now tacked on and tied in to the space frame. I had an old door kicking about so I put it on and made the reinforcements for the latch and hinges. I’ll have to borrow a door off my GTI to do the other side.

Shut lines are even good!

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More bodywork trimming today.. getting the front end ready to go back together and tidying up the sills. Removed 7kg of metalwork. :)

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So I moved on to the next job, which is to remove what’s left of the sills ready to be boxed in for the exhaust. While I was at it I removed a load of meat from the door & windscreen surrounds - I only need the apertures for both so everything else was chopped out. 

The bodywork started off at 18.2kg and I chopped 6.2kg out, leaving 12kg. Most of that was out of the front so will be good for the weight distribution. The roof skin will be replaced with carbon which should hopefully save another 2kg.