1936 Bugatti Atlantic Replica Project RABUGGI - Radiator Shell & Hood

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

[12-16-10] Skinning 2nd layer (hood "bezel")

[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.

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

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

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

[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.

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

[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.

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

[11-05-11] Developing the process for a clear resin covered RABUGGI "radiator" badge

[05-02-12] Completed RABUGGI radiator badge... [Here's a .PDF of the graphic.]

[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.

[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.

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

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

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

[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.

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

[06-16-15] Hood form framework...
An initial 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.

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

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

[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.

[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.

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

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

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

[07-18-15] Hood top panels with initial trim, lying in place...
Yes, this looks like it will work. [Sketch of hood hinge scheme]

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

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

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

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

[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.

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

[10-20-15] Hood panels assembled... (hood center hinge support/locating detail)
Readily available Jeep CJ hood hold-downs in polished stainless steel look pretty correct.

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    Last tinkered with May 9, 2020