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Discussion Starter #1
Here is my latest project. I am hand fabricating a three dimensional trident. It will be 12 inches tall and rest on a concave carbon fiber sheild. I will be incorporating the maserati logo at the top of the sheild. The trident will be fabricated from a back bone of balsa which will have a urethane foam built up to be sculpted into the final shape. Once the foam and basa are sculpted to the desired shape, they will be sealed with black epoxy. This epoxy will also act as the tack cote to which several peices of 4x4 Vtwill carbon fiber will be meticulously hand placed and laminated. Feel free to chime in with any questions as well. I hope everyone enjoys this.
 

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Discussion Starter #2
The first pic

I begin by drawing the trident on paper to the exact size I want it to be. I will then cut the shapes out and use them as stencils for the balsa back bone. I also went ahead and cut out the maserati letters with my exacto knife. And yes it would have been easier to have it done at a vinyl shop with a plotter but i want to do as much of this thing by hand as possible. Anyone can go get a sticker made by some computer, how many people can keep a steady enough hand to cut their own with a hobby knife?
 

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Discussion Starter #3
Here are the back bones being cut out of 1/16 balsa sheets. After the shapes are cut and the edges are refined and evened out, i will lay around the perimeter of each peice some aluminum tape used commonly in the aircraft industry, "sometimes referred to as speed tape." This tape will act as a dam in which i will fill with a liquid 2 part 4lb density urethane foam.
 

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Discussion Starter #7
Thanks big foot. I know it looks rough right now, almost cartoonish, and it only gets worse looking during the next phase of this process. But its nothing but improvement from then on.

Spyder: I plan to use this as a demo peice. I am going to bring the final product over to the dealership in FtLauderdale and see if they like it. The reverse side will be a Ferrari sheild.
 

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Discussion Starter #9
The red strip at the top is only red vinyl tape. That area will be painted to match the horse and I will be adding a pin stripe or 2 that will follow the sides and lower perimeter of the sheild. The top will also have the lettering of the Ferrari logo exposing the carbon fiber beneath the paint. And i cant seem to get my pics to turn in the position i want nor can i upload more than 1 pic at a time for some reason.
 

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Discussion Starter #10
Here are a few shots of some more progress. I hand cut all of the balsa with an exacto knife after tracing the outline from the paper stencil.
 

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Discussion Starter #11
Here is a shot of a backbone with the metal tape dam in place. This is how I create the cavity in which i will fill with foam. The metal tape works great at redirecting the pressure created when the foam expands. All of the excess will be forced upward instead of outward, and the extra wide tape gives enough height so that I can use the excess to fabricate another 2 or 3 of these as well.
 

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Discussion Starter #12 (Edited)
The foam rose so high, i thought for sure it was going to spill everywhere. Luckily for my kitchen counters, it held its shape, even after rising beyond the tape. I have 5 kids. 2 of them are babies, and Im a stay at home momguy so a vast majority of the work you see is done in my kitchen while they sleep. And dont be surprised to see some crayon artwork on my floors, walls, body, shoes etc. PS; it doesnt matter how many crayons you throw away there is ALWAYS another one stashed somewhere.
 

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Discussion Starter #15
I almost have all of the carbon bonded to the trident. And yes the letters look like crap. These were my first attempt at hand cutting vinyl. It will not be used on the final piece, only for reference in these pics. I have another which is cut to perfection and will be used to paint the letters in place later.
 

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Discussion Starter #16
Here is a rough peek at the final concept of the Ferrari side. I may get a little more intricate with the stripe, but not too crazy. My goal is to remain elegant ovah heah. Simple but not plain. Exotic but not overly extravagant. The black vinyl letters will be laid down first. The red paint will go over the vinyl. Then the vinyl will be peeled up revealing the underlying carbon so that the Ferrari lettering will be exposed carbon.
 

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Discussion Starter #17
I am still working hard at finishing this thing up ,when my schedule permits it. Its almost 3:30AM here, and "my little rooster" as I call her will be waking with the rising sun. I will be posting more pics soon, but in the meantime I thought everyone might enjoy something a little more pleasing to the eye. This is one of my finished projects, who can guess what this is???
 

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Discussion Starter #20
The center spear. By far the most challenging piece of this entire project. When it's completed there will be 18 individually placed, hand trimmed pieces of carbon fiber surrounding every surface of this sculpture. There are a few more sections of carbon that need to be put in place, so hopefully I will be posting some more shots of that soon.
 

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