Category Archives: Automotive

One Small Trailer & a Teardrop

By Mike Lance

My good friend Orrin and I have been messing around with WEST SYSTEM products for the past forty years. After building and racing a hydroplane in the Seventies, we built a 21′ cedar strip two-person kayak in 1980 and an 18’6″ cedar strip canoe in 1981. In 1981 we placed second in the 320-mile canoe race across New York state using our kayak. Both boats are shown in May/June 1985 edition of The Boatbuilder, Gougeon’s precursor to Epoxyworks.

After I had competed in the Sikaflex® Challenge races over a number of years, a book on teardrop trailers caught my interest. Having some plywood left over from the Seventies I started thinking that I could build a small camping trailer for my wife and me. There existed a real problem: would my wife actually sleep in something this small? With encouragement from my daughter, Karen, to build it for the sheer fun of building, I mentioned the idea to my wife, Terry, saying that I would understand if she declined. Her response: “How dare you try and exclude me from your next adventure?” Game on. Continue reading

First Place winner at MITES

Pedal Car

By Jon Fox

Epoxyworks 41

Cover Photo: First place winner at MITES at both the regional and state level.

For the past two years, the Drafting/Pre-Engineering class I teach at Tuscola Technology Center in Caro, Michigan has been invited to participate in a contest sponsored by Summit Racing.  Students build a custom pedal car that is displayed and judged at the AutoRAMA show at Cobo Hall in Detroit. Summit Racing either supplies participating schools with one of their stock pedal cars which can be modified and customized, or students may build their entry from scratch. We constructed our entry from scratch both years. Our first car was inspired by the Delehaye roadster and built of aluminum in an Art Deco style. Continue reading

The Carbon Fiber Look

By Daryl Burnett

I was talking to my friend Blake Rivard about doing something different for his motocross bike. We settled on a carbon fiber air filter cover. On his bike, the air box sits just below the handle bars where the gas tank usually is. I started with removing the plastic piece and cleaned it so no dirt would be present in the final product.  The original air box would serve as a mold for the finished piece. Continue reading

Dirt Bike Loading Ramp

By Daryl Brunette

A dirt bike loading ramp is very bulky and heavy, but important for loading everything you need in motocross. You can just use a wooden board thick enough to support the weight of your bike, or you can buy expensive aluminum ramps. But I (Daryl) wanted to build one and give it a personal touch, making it lighter and stronger. Continue reading

Goshen students

588 Miles Per Gallon

By The Students of Goshen High School’s Engineering Design & Development Class

We are a group of students from Goshen High School in northern Indiana and for the past six years we’ve had the opportunity to design, build and test high mileage prototype vehicles in a class called Engineering Design and Development. Year to year this program serves about 30 students aged 15 to 18. We begin with little to no background in an automotive or engineering technology background, and through the course of this program learn many new skills. Continue reading

What’s New at Staudacher’s Shop

By Don Gutzmer

Aircraft designer and builder Jon’s Staudacher’s newest project is an enclosed wood trailer for his new race car. Jon designed a trailer to be suitable for hauling his race car and living in over a weekend at the race track. The trailer was built by scarfing and gluing together individual pieces of wood to form a beautiful natural wood finished race car trailer. Jon always surprises me with how innovative he is with projects. After Jon built an open wheel race car he had a design in mind for a new plywood trailer. Continue reading

Fabricating an Air Scoop

Using the Lost Foam Method

By Brian Knight

I used lost foam construction to fabricate a fiberglass air scoop for my son’s Formula Continental C race car. Our project started because a modification to the shape of the race car body necessitated the construction of a new air scoop. The air scoop is bolted to the car body so if either the air scoop or the body is damaged (a very likely scenario), the repair will be simpler. To fabricate the scoop, I made a Styrofoam male mold, surrounded the mold with fiberglass, and then dissolved the Styrofoam to leave a hollow part. I used Styrofoam to build the male mold for several reasons. It is readily available at most lumberyards, it is easy to shape with files and sandpaper, and it is easy to dissolve with lacquer thinner.

Continue reading

Auto Body Repairs with WEST SYSTEM Epoxy

By Tom Pawlak

Ten years ago the rear fender on my son John’s 1991 Honda Accord was damaged just forward of the wheel. It had been repaired at a local body shop, but four months later the same fender was rusting. I took it back to the body shop. The manager apologized and agreed to redo the job, but said there wasn’t much metal for his technicians to work with because the car had rusted significantly prior to the accident. He couldn’t guarantee that it wouldn’t rust again.

I asked him if he would consider painting both rear fenders in exchange for me rebuilding the problem fender, and he agreed. I planned to rebuild the fender myself with epoxy, and also rebuild the rusted fender on other side. I knew I’d be able to do a much better job with WEST SYSTEM Epoxy and fiberglass than with the polyester-based putties the auto body repair shop had used. Continue reading

A Magnesium Crankcase Repair

By Rob Van Mullekom

I work here at Gougeon Brothers, Inc. as Operation Supervisor in the epoxy department where we do production mixing, assembly, packaging and quality control of the epoxy products. A lot of the guys I work with here ride motorcycles. In talking with these guys, I found out that it is not uncommon to punch a hole in the ignition housing cover. In fact, that’s what happened to my bike. Continue reading