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1936 Bugatti Atlantic Replica Project
RABUGGI - Radiator Shell & Hood

rad. shell model rad. shell model
[11-27-10] Radiator shell model start. We can take this to the basement and maybe get some done indoors during the winter.
The bottom is truncated for our S10 donor frame lateral, one of the known required deviations from a correct Atlantic shape.

rad. shell model rad. shell model
[12-10-10] Skinning radiator shell model with 1/8" Masonite. Soggy wet Masonite just barely makes the top radius bend.

rad. shell model
[12-16-10] Skinning 2nd layer (hood "bezel")

rad. shell model rad. shell model
[12-25-10] Filling, smoothing, sealing, sanding...
The bevel on bottom left corner is for clearance to the S10 original engine mount which is offset to the right 1/2 in.

rad. shell model rad. shell model
[05-24-11] Radiator shell model waxed and ready to gelcoat and lay glass for mold


Radiator shell mold layup
[06-29-11] Radiator shell mold layup in progress

radiator shell mold - rear radiator shell mold - front
[07-06-11] Radiator shell mold halves, popped off of the pattern...
The pattern and all that labor is now junk.

radiator shell mold - ready
[08-02-11] Radiator shell mold, trimmed, assembled, waxed, and ready for part lay-up...
This will be an awkward "inside" lay-up, but manageable for our low volume.


radiator shell 1
[08-15-11] Radiator shell raw part coming out of the mold

radiator shell 2
[08-15-11] Radiator shell raw part -- the first real body part
The blue line is modeling clay used to fill a mold parting line gap.

radiator shell 3 radiator shell 4
[08-18-11] Radiator shell - trimmed (with a taped on paper RABUGGI badge)

logo print blank, nibbler sealing blank
casting resin bending the blank with mount plate
[11-05-11] Developing the process for a clear resin covered RABUGGI "radiator" badge

badge (back detail) badge (front detail)
[05-02-12] Completed RABUGGI radiator badge

PVC radiator cap
[01-22-13] Simulated Type 57SC radiator cap pieced up from PVC pipe materials... Form is actually pretty good, but size came out too big.

Radiator cap in lathe Aluminum fake cap
[01-22-13] We'll go with a turned aluminim fake cap, more of a Type 57 style. Not as correct in form, but easier and more durable.

Hood interface Hood side beams
[06-27-13] Radiator shell mounted, with steel hood interface side beams

Radiator shell reinforcement
[06-27-13] Radiator shell steel reinforcement for front fender support

Hood side beam Hat section channel
[06-27-13] Hood interface side beams & radiator shell to firewall hat section channel...
The hat section channel was sheared and pressed by Manowske Welding, Fond du Lac, WI.

Cowl fairing rework
[06-27-13] Ugh! We somehow missed the mark for the cowl fairing in the pattern,
so some rework is required for fairing the cowl / hood / radiator shell planform.

Hood mock-up Hood mock-up
[07-04-13] Poster board mock-up of aluminum hood panels


Hood form framework
Hood form framework
[06-16-15] Hood form framework...
An original effort to make the hood panels from aluminum was a colossal FAIL.
We'll make wood mold forms directly and lay-up the upper hood panels in fiberglass.

Hood form - skinning
[06-26-15] Hood forms -- skinning with Masonite

Hood form - sanding
[06-26-15] Hood forms -- sanding, checking

Hood form - filled, sanded, sealed
[07-12-15] Hood form - filled, sanded, sealed...
Don't know how that low spot got there (on both sides), but it can be faired with some plaster fill.

Cutting hood side panels
Cutting hood side panels
[07-18-15] Laying out & cutting hood side panels...
These aluminum panels are useable parts from the failed attempt to make an all aluminum sheet hood.

Hood top panels - gelcoat
[07-15-15] Hood top panels - gelcoat

Hood top panels - cloth lay-up
[07-18-15] Hood top panels - cloth lay-up

Hood top panels - raw out of mold
[07-18-15] Hood top panels - raw out of the molds

Hood top panels - partially trimmed, lying in place
[07-18-15] Hood top panels with initial trim, lying in place...
This looks like it will work.

Hood center hinge being located and drilled
[09-01-15] Hood center hinge being located and drilled

Hood side panel drilled and ready for riveting hinge
[09-02-15] Hood side piano hinge and panel drilled and ready for riveting

Hood side panel with piano hinge flush riveted on
[09-02-15] Hood side panel with piano hinge flush riveted...
Stainless and aluminum piano hinges and AN rivets are from AircraftSpruce.com .

Hood top panels getting some stiffeners
[09-04-15] Hood top panels getting some stiffening ribs

Cowl rework - hinge clearance channel
Cowl rework Cowl rework Cowl rework
[10-01-15] Cowl side wall rework for a clearance channel for the hood side hinges...
This was an oversight in the initial layout, patterns, and molds, so we need to add it now. ...not too bad.

Hood side panels with flattened expanded mesh
[10-20-15] Hood side panels with flattened expanded aluminum mesh...
Expanded aluminum grille material is from Onlinemetals.com .

Hood top panels getting some stiffeners
[10-20-15] Hood panels assembled...
Readily available Jeep CJ hood hold-downs in polished stainless steel look pretty close for the Atlantic.


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