Category Archives: Automotive

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 – GBI Technical Advisor

Aircraft designer and builder Jon’s Staudacher’s newest project is a wooden enclosed 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.

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Auto Body Repairs with WEST SYSTEM Epoxy

By Tom Pawlak — GBI Technical Advisor

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. 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 — Vice President of Technical Services

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 — GBI Technical Advisor

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

Scale Ferrari

Building a Grandson’s Formula 1 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