Otomoto BLOG

The plastering process takes longer than you might expect, requiring many re-applications to get a smooth and consistent surface.
The polycarbonate sheet you see on the window makes it easy to get a sharp, straight line between the panel and the window, so you won't notice that they don't meet.

























Here the panel between the headlights is getting shaped, but it's hard to see what the headlights will look like with everything in white
























Here's the basic shape of the headlight covers, they will be heat-formed to match the curves and sit neatly over the headlight and indicator/parklight.
The white parts under the cover will all be satin black so the whole panel should look quite dark (especially with all the plaster dust removed)
























Doing a project like this you find yourself looking at it and thinking about as often as you are actually doing something. After staring at it for most of a day I realised that the line of the upper door panel was wrong. Although it was perfectly level, the way it tapers in creates the illusion that it slopes upward towards the front of the car. To fix this, the line will be raised 15mm at the back and dropped 15mm at the front. This also makes the imaginary extension of the line meet the top of the wheel arch (shown here with masking tape).
This photo also shows how the side step has been reshaped so instead of being flat along the side, it twists inward as it goes along,
























The rear part was cut away with an angle grinder metal disc. To drop the line at the front it's time for more expanding foam.
























The new line complete. It may not seem like a big change, but it makes the whole design look more cohesive.
























Another important line, the shutline between the bonnet and the nose panel was made perfect with a sheet of 3.5mm polycarbonate jammed between the two.



























The same technique gives the hatch a straight and sharp shutline. We are really getting into the detail stages of the project now. Our next update may take a little longer, as the blog has caught up with present day. Thanks for reading!