This is the ski portion of the new body halves. This piece also establishes the datum line for every measurement taken from this point on. It is two pieces that are 41-1/2" in length. It's constructed of 1/8" X 1/2" X 1/2" mild steel angle and 1/4" diameter rod formed on an anvil.
With the suspension set to the proper height and the ski in place the front hoop was bent that forms the front edges of the body halves and connect to the front fairing. The hoop was welded onto the ski halves while in place on the bike. Afterwards I cut it in the center to separate the halves.
This shows the margin set for rear tire clearance. The bodywork is first molded intentionally a little long to allow trimming right up to the edge of the rule book.
This picture illustrates well the demand for space. Note the oil lines for the turbo and the engine drain plug. When the bodywork is finished and installed there will be less the and 1/8" of clearance.
With the ski and the front hoop in place the perimeter shape had been established. The contours were set with evenly spaced ribs that were constructed of anvil formed 1/4" steel rod and 1/8" X 1/2" mild steel flat stock. I was going to laminate the halves in sections and it was important that the forms remained rigid throughout the process whether on the bike or on the table. At this point we hadn't chose a tail piece design so I picked a neutral location at the end the body halves hoping it would allow me to easily tie it in later.
This shows the leading edge of the exhaust cutout and the blister or bulge for the pop-off valve.
The contour for the upper lip was created in 1/8" steel rod. Note the contour around the pop-off valve also.
Very tight behind the front tire. All I could do was split the differences. Give a little to the intercooler and give a little more to the front tire and fender for travel and turning. Very close tolerances.
The blister for the lower left corner of the intercooler.
With a piece of 1/4" I.D. fuel line taped to the tire there was exactly 1" space between the imaginary fender and the imaginary bodywork.
The halves clamped together on the floor.
Right side view.
The table heads performed two functions. On a saw horse they provided extra support to the form and allowed horizontal laminating of the glass. The other function was when the halves were joined together it allowed the forming of the bottom ski in one continuous surface. And, it made it possible to laminate the scoop area as one piece in the gravity correct position.
The two halves joined in the position they would be to form the ski of the bodywork.
This view shows the outer shape of the bike if it was turned upside-down. Classic tuna shaping as tight as I could make it to the massive innards it encloses.