Making a Tee Car RC Car For the Stade Toulousain Rugby Team and its Peugeot Partner
Peugeot has been a major partner of Stade Toulousain for 22 years, and wanted a Tee Car in its image. They chose the new Peugeot Expert from the Peugeot Utilitaires range .
The order is finalized this summer and I started construction late August. I detail here a method to achieve a fiberglass body without tools , with just a little patience.
the master or main model
it is made of medium, pressure-agglomerated wood fibers (MDF)
shots glued on medium boards (MDF) then cut
grooves on the back allow you to bend medium boards
the plans of the windows and details are milled with a freehand milling machine
blank assembly, profiles are used to check the different sections of the model
the front is a superposition of medium boards follow the profile
the side planes are machined at the router / milling machine
detail of wheel arches
boards are lightly sanded
sculpture of different lighthouses detail, putty used to add small shapes
the model (master) is primed with a polyester primer
then painted with automotive polyurethane paint
polishing to obtain the smoothest surface possible, sandpaper 800 and 1000 then polishing paste
the master is presented on the chassis of Traxxas X MAXX 8S
Polyurethane resin is poured into areas where joints between planks are too thick. this can prevent movements and cracks
The Fiberglass mold
once a master realize it is necessary to make a mold (here dismountable: in serveral parts)
the mold receives 6 layers of wax
as the master presents countercuts, the mold will be in 5 parts. Seals are made of Plastiline (modeling clay that does not dry …). There are imprints made with a ball that allow different parts of the mold to be positioned without risk of shift.
Mold gelcoat is applied on the front and back which are made at the same time
a few layers of fiberglass (matte) and polyester resin
the joint plans are removed and new ones are made for the sides
gelcoat and fiberglass on both sides
once the ready sides we can directly do the fifth part of the mold. After removing jointing planes, wax the area before the gelcoat
the edges of the molds are deburred to the grinder
the 5 parts of the mold are waxed in turn before and after reassembly
drawing of a car body RC fiberglass
Once the mold is made, we can make several prints
applying the gelcoat with a brush
the fiberglass pieces are precut
and weighed to estimate the amount of resin to be prepared for each layer
3 layers in this version, we can vary the number and the material of the layers according to the desired resistance
wedges help to separate the parts of the mold, with a good waxing there is no resistance
first piece of mold outlet
and the second for training, ready to be sanded to erase joint plans
RC Car Body Paint in Fiberglass
unlike the transparent plastic bodies (Lexan / PC) that are painted by the interior, those made of fiber are painted from the outside like the real cars, with the same paintings and techniques
the bodies are primed then sanded
2-layer paint according to the Toulouse Stadium color code
windows and bumpers are painted
a sheet of stickers is made and printed on vinyl with resistant inks
Stickers placed and body mounted on custom made supports. switch must be easily accessible
Peugeot Expert Tee Car: the master, the mold and the 2 fiberglass prints
the box to wear the Tee Car during matches
with its battery drawer, radio and charger
Peugeot Expert Tee Car Stade Toulousain Scale 1: 6.44
delivery tee car at the Toulouse stadium 29 days after the start of production!
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