Even though my Laptop's iPhone driver is malfunctioning, i'm going to start on with the thread with whatever pictures i have saved here and there....
This post is related to do with the manufacturing of the composite body. Note that this technique is very helpful and can be used to make almost anything using fibre glass, carbon fibre or any such material...
To start off, you first need a CAD model of your intended design. The CAD or CAE (computer aided engineering) package I have been working on is Wildfire's ProEngineer (V4).
Attached below is a PRO-E image of the Class 1 A car Assembly. However all you need for the body is the CAE file for the body.
Once the CAD file for the body is complete, you need to make cross sections to mark out the profile of the body.. Note the picture above is of a previous body. The one I worked on is recent and the latest pictures are on my iPhone that i shall fix soon...
To get the profiles you cross section your cad file at equal length intervals to get a balanced idea. The more the sections the better the detail however it comes with the cost of much more work. Once the profile intervals is decided, you take out cad drawings for the profile sections.
Once the drawings are ready...you are set to start doing some manual labour.. First off you need Timber beams and sheets. The rectangular timber beams act as a base for your model giving it strength, location and regularity.
The timber sections are then nailed to a base plywood sheet and placed on a work-top to allow easy access all around the project. The profile sections are then cut from the timber sheets. The best way to do this was to take out 1:1 drawings from the CAE and tracing them on the timber sheets. Once the sections are cut, you need to make two slits at the bottom of each profiling sheet to allow it to be located on the beams. To maintain geometry, it is best practice to use some square sections of the beam and nail them between the timber beams and profile sheets. This will ensure the profile sheets are perpendicular to the base. The entire profile across the length of the design is then completed. Please see image below.
Once the profiling is complete using timber wood. The empty spaces are filled using engineering grade foam (the sky blue material). This material is hard enough to maintain geometry yet easy to cut and shape using the correct tools. (small electric saw, belt sander etc)
(you can see Bilal with a deadly mallet, a Pakistani colleague and a dear friend at university - very passionate about FS aswell)
Once the empty sections are filled with the engineering foam and after considerable man-hours of work the foam takes shape. Note at this point the surface of the foam doesnt have to be very smooth. Once the foam is set and ready, An epoxy resin mixture is poured on top. This mixture is spread evenly across the body. The viscosity of this resin is extremely important (extremely viscous will not let it spread properly and the coating will be too thick, low viscosity will make it drip like water). Therefore once the resin is poured over the entire build area, it is allowed to dry overnight (usually with the aid of electric heaters). This is shown in the image below.
Once the drying of the resin mixture is complete. It is carefully sanded and finished. The better the finish of the surface, the better the quality of the body. Extreme attention is payed to the finishing at this stage.. Once carefully finished and the surface quality is acceptable, the die is ready. This is the completed die for the body. Now the body panel can be made by spraying carbon fibre or glass fibre on the die. This die can also be reused again multiple times. Remember in composites, the die is the most important part. Our university had robotic carbon fibre sprayers that are controlled through computers and require no manual labour. (You can see another colleague and friend of mine posing next to the completed die below)
Note:If you can reach the completion of the die, It is easy to find fibre glass specialists in Pakistan who would spray it for you to give you the body.
HOPE YOU GUYS ENJOYED...I SHALL KEEP POSTING!!! WATCH OUT 
