batbuilder's LP640 called "No Mercie"

[batbuilder]

We had already cut a gas cap lid when I heard I could buy one from John Watson. Suppose to get it tomorrow. Yahoo....

[batbuilder]

The tape goes all the way around the inner door. This was an idea I have been toying with. The ability to access the inner door after the car is painted.

[batbuilder]

Here is a new lip being created to allow the outside door skin to be removed. I use the tape to create a barrier from having the new fiberglass from bonding to the interior door panel.
Really important to cover the latching mechanism to prevent resin from gumming up the works.

[batbuilder]

Here is the door latch area that was cut out to accomodate this little latch. Its going to have to be reconstructed.

[batbuilder]

The gap at the back of the door was closer to the jamb than the front so we decided to use the back to line up the door skins.
Trying to line up this dang door is a little frustrating. Big problem is the door skin needs to be arched outward at the front of the door skin. The curve is too shallow.

[batbuilder]

The top window frame was taken off since it was at a different angle to the bottom of the door skin.

[batbuilder]

Wow had a really nice talk with John Watson. Has a really deep knowledge of fiberglassing and a long history in the industry. Buying a gas cap for now but hoping to do bigger business in the future. Great talking with you.
 Here's our door skin not linning up with the body lines. Needed to have more of an arch in it.

[batbuilder]

filled all the voids with more chopped fiberglass. Doesnt look pretty but its fricken stuck on there...Lol

[batbuilder]

One quick motion using the set screws to align the headrest and then clamp. I'm not so proud to say first screw went in clean. Second screw could not find the hole. Should have played with it a bit before. No time so I eyeballed it and clamped it. I am a good 3/8 of an inch off. no use worrying about it this is never coming off....So we will realign by building up and sanding down.

[batbuilder]

this was all about timing. Got everything ready and just feeling the resin solidifying. it set up good in the gatorade bottle

[batbuilder]

Again its important not to contaminate the mat with oily hands always use gloves. Mat was put on then resin applied to sanded brace. A mixture of radom cut fiberglass and powdered fiberglass is added to the resin This creates a mush right before we screw and clamp it together. Its solid and NOT coming off....Lol

[batbuilder]

Here's the fiberglass matt cut and ready for the resin. Two layers. It was important to get a good bond to the inside of the headrest. So sand and acetone first

[batbuilder]

Hey usmc-butler, thanks for checking the BK out. yeah these builds are not for the faint of heart in terms of budget. The front steering has three options. Option one is to use gears, sweeps, pillow blocks, PTO shafts with power steering unit and pump adaped to the clutch. Looking to get a price on that but it will be the most expensive but cool looking. Option number two will be hydraulic steering with pump, valves and a lot of stainless hydraulic hose. Less expensive. and third option will be large linear actuator at steering arms. Least expensive but not really that fancy. I have a buddy that has an industrial machine shop so I hope the steering and drive is within budget. Those front pipes are all machined through so that the fit is super tight, squared and eliminated the need for a weld up jig. To me the fabrication of the Big Kahuna will be the most complex for me to date. I have pics of the uprights for the frame that are beautiful and will be in my second batch of pics. Im a lot behind in my posts. Thanks so much for looking and commenting. Makes the process fun...dave

[batbuilder]

Thanks NuCountry, I have a lot of flat panel fiberglass pieces that go on this beast. Its been a collaboration of what me and a bunch of Dark Knight enthusiasts think the Batpod should have been built like. Thanks again means alot coming from you....Love your fiberglass work...dave

[usmc_butler]

You have more in tires and metal in that thing then I do my whole project ! How do you plan on steering that thing ?!