For each of our 2-year build cycles, RX2 focuses on different iconic cars in history to take inspiration from and bring back to life. This season is our first year as a team and we have decided to replicate the design of the Mazda 787b- winner of the 1991 Tour de le Mans. Below, showcases our process and progress: from our initial CAD model, to the current state of our project. As of April 2026, we have almost finished sanding our shell, and are working on our chassis and suspension.
Process &
PRogress
Progress from November
CAD Model
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CAD Model /
CAD MODel
In August, our team 3D scanned a model of the Mazda 787B to create the profile of the shell. We then used a surface meshing tool to create the final CAD model of the shell.
In October, we divided the CAD Model into 1 and 7/8th wide inch slices. In total there were 72 total slices. We printed each of the slices onto a sheet of paper and used spray adhesive to attach them onto the individual foam slices. We then jigsaw cut each individual foam slice and pieced them together to start sanding according to the CAD model.
Foam Slices
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Foam Slices /
Foam SLices
Progress Check
Progress Check
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Progress Check /
Prepping
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Prepping /
Prepping
In December, we sanded the profile of the car down to smooth out the mold. Afterwards, we used joint compound to assemble all 72 slices together to create a smoother, more accurate depiction of our final product. Then, we applied a combination of joint compound and primer to the exterior of the car to prepare the mold for carbon fiber.
In February, we cut up our 3k twill carbon fiber to use as our shell for the car. Carbon fiber is the lightest and strongest composite material available to us, perfect for creating an aerodynamic shell for our racecar. We measured out the resin and applied an initial to our car. We then continued with the process of applying resin, then carbon fiber, then resin again three times. Afterwards, we applied Pee-Ply (the thin material depicted in the last photo) to the top layer of the shell in order to weigh down the resin. Then, we left it on to dry for 24-72 hours.
Carbon Fiber
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Carbon Fiber /
Carbon FIber
Progress Check
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Progress Check /
Progress Check
