I was talking to my friend Blake Rivard about doing something different for his motocross bike. We settled on a carbon fiber airbox (air filter cover). On his bike, the airbox sits just below the handlebars 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 airbox would serve as a mold for the finished piece. Continue reading →
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 →
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 →
Aircraft designer and builder Jon Staudacher’s newest project is a wooden enclosed trailer for his new racecar. Jon designed a trailer to be suitable for hauling his racecar 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 racecar 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 →
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.
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 →
I accidentally punched a hole in my motorcycle’s magnesium crankcase or ignition housing cover. A lot of the guys I work with also ride motorcycles, and in talking with them, I found out that it is not uncommon to punch a hole in the crankcase. I work here at Gougeon Brothers, Inc. as Operations Supervisor in the Epoxy Department where we do production mixing, assembly, packaging, and quality control of WEST SYSTEM® Epoxy.
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 engine covers in the wrong sequence which caused a tab to snap off. Continue reading →
Above: The repaired camper panel is back in place on the camper. A coat of Krylon Fusion® textured, plastic-compatible paint completed the camper repair.
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 →