Process & progress

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.

We divided the CAD model into 1⅞-inch-wide slices — 72 in total. We printed each slice onto paper, attached it to foam with spray adhesive, jigsaw-cut every slice, then pieced them together to start sanding to the CAD model.

All slices cut and assembled into the full-size body.

We sanded the profile of the car to smooth out the mold, then used joint compound to join all 72 slices into a smoother, more accurate shape. Finally, we applied a combination of joint compound and primer to the exterior to prepare the mold for carbon fiber.

We cut 3K twill carbon fiber for the car’s shell — the lightest and strongest composite available to us, perfect for an aerodynamic race car body. We measured out the resin and applied an initial coat, then repeated resin, carbon fiber, resin three times. Finally, we applied peel ply to the top layer to draw out excess resin and left it to cure for 24–72 hours.

The carbon fiber shell, laid up and cured.

By April we had nearly finished sanding the shell and moved on to the chassis and suspension. See the build through to race day in our monthly technical updates on Our Journey. Read the updates →