Category Archives: Automotive

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

Blake Rivard

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

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

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

Plastic Engine Cover Repair

By Jeff Wright

My wife’s 2000 Audi TT has a very sleek shape, and these smooth lines are carried under the hood with molded plastic engine covers that provide a very clean looking engine. Unfortunately when I was servicing a burned out bulb, I attempted to remove the covers in the wrong sequence which caused a tab to snap off.   Continue reading

Camper Panel Repair

By Tom Pawlak

Todd Lynch, one of our valued employees, brought in a damaged plastic panel from the back end of an 11-year-old pop-up camper and asked if it was worth fixing. It came from his hunting camper which had been rear-ended. He just wanted it to be functional. The impact had made cracks at nearly every screw hole for holding the panel in place, making it doubtful it would last another trip down the highway. Continue reading

Building a Grandson’s Formula 1 Ferrari

John White’s grandson takes the wheel of his electric-powered, scale Ferrari.

By John White of Fife, Scotland

When the first grandson arrives, any grandfather knows he now has the chance to fulfill the dreams he had as a boy. A Formula 1 racing car would do for starters. A small model purchased for £4 was the starting point. The car will be ready for his third birthday so plenty of time (or so I thought). Continue reading