"Chaffee" new shuttle build.

[Sync]

[attachment=1]chaffee-views.jpg[/attachment]After building tiny single person mutants to get around in the past I decided to try for a real art car this year. I'm beginning to understand how art projects can get out of hand ; ) . Was originally going to get a cheap used golf cart and slap a few panels on it with some decorations. Well, turning out a bit different. I saw two other Star Trek Shuttles on the playa and decided to go for it. I'm going to chronicle the build in the hopes of passing along what I learn in the process. So, here's what the Type 10 shuttle "Chaffee" is supposed to look like and the base vehicle it will be mounted on;

[Sync]

[attachment=2]ctop.jpg[/attachment][attachment=2]ctop.jpg[/attachment][attachment=2]ctop.jpg[/attachment]The original pattern for the body was going to be based on a paper model pattern out on the internet. I figured a few sheets of coroplast could be used to up-scale it from paper to mutant size. I built one of the paper models, it was ok, but very simple. Then I remembered in 3d modeling programs there is a function that lays the skin of any object out flat for texture painting. So I decided to create a more realistic 3D model and have the computer lay out the pattern so it could be cut on 4x8 sheets of coroplast. Here's a sample of the 3D object, some of the pattern laid out, and the paper mock up of the computer Chaffee;

[Sync]

[attachment=0]IMG_0150.jpg[/attachment]The pattern for the shuttle was divided into patterns that would fit on 14 4x8 sheets of coroplast. It just so happened my son is in a special program that has a Shopbot. This wonderful computerised cutter proved to be the perfect lay out tool for cutting the panels. Here's one panel being robo cut.

[Sync]

[attachment=0]IMG_0152.jpg[/attachment][attachment=1]photo-9.jpg[/attachment][attachment=1]photo-9.jpg[/attachment]Next steps have been to bend the parts into shape, secure the shapes in place with duct tape, and then hot glue the seams and braces in place. Turns out you can glue coroplast, just takes the right industrial glue sticks and an expensive glue gun. The pics show the nose section taped together, then fully glued with the main body section beside it. Looks like overall when the pods are added the shuttle will be about 15 ft long.

[Ugly Dougly]

That is teh sick.
Can't wait to see it all come together.

[Sync]

Working on the shell in installments each week. Basic body without the engin pods is almost complete. Dune buggy base gets here in a few days.[attachment=0]chaffee 3-3.JPG[/attachment][attachment=0]chaffee 3-3.JPG[/attachment]

[burner von braun]

Very cool Sync! I will enjoy watching your progress here, and if I'm fortunate enough see you on the playa, I'll replicate you a cold beer. I am already inspired by your pattern/shopbot approach to the project.

[renojeff]

Very cool build. Why did you decide to go with a dune buggy base vehicle rather than a golfcart base?

[Savannah]

Really fun to watch this come together, Sync!

[Sync]

I've been looking at base vehicles for a few years now. I wanted a duel use set of wheels so I can play with it off road when not at burning man. Ideal base would have been an Argo 8 wheeler, but way too expensive. Golf carts have some inhernt problems IMO. Electric just doesn't quite make it on the Playa. As much as I've tried with the two small electric MV I made so far, the amount of power needed for recharging and the charge times just make them a pain. Gas powered golfcarts just seem underpowered as well. I wanted enough power to tow other MV cars if needed (had this done for me one year and was grateful) or maybe be able to tow bikers or boarders. I also wanted a low profile to mount the shell on. The KIng Cobra cart I'm using is one of the only made that meets California clean air green sticker standards, and its relativly cheep compared to things like a Polaris or ATV. The shape of the roll cage also follows the general shape of the Chaffee, which will make bolting the shell to the frame eaiser. At the same time the engine is only 150 cc so it wont be too obnoxious on pollution or gas.

Buggy modifications for the Playa will be enhanced muffler system to make it quiet, performance air filter system for the dust,and a racing fan to make sure there is enough airflow in the shell. Lighting system is going to replicate "warp core" effect in the front and back of the engine pods, and several sets of computer controlled LED ropes. Amazing the stuff you can get cheep on ebay .

[MacGlenver]

Hmm, sounds like you need to think through vehicle selection a bit more...

[Sync]

I was thinking; there's this site called Kickstarter that web funds art projects with donations. Ther are a bunch of Burning Man projcts on the site already. Maybee ask for 2.8 trillion for an actual warp drive?

[SnowBlind]

Maybee ask for 2.8 trillion for an actual warp drive?

Just make sure you don't have a core breach...

[Milayna]

This is so cool! I'll be watching for it out there

[Sync]

OK, so getting the dune buggy took half-way to forever. The one shipped was a cheep POS, so had to be sent back to be replaced with another POS, but this one was fixable. The origional body for the shuttle was too long for the buggy body, so it was shortened from 12 feet to 10, the engine pods will have to be a little smaller as well, but hey, would have been delusional to think it was going to be perfect. The above pic is the shell just sitting over the buggy. The black lines are where the internal support struts are going to be, red area is where the doors are going. So far so good. Ordered a special K & N air filter to replace the stock filter on the engine. Last time I took a GY6 clone engine to the playa it choked out on the dust by Wed.

Next few weeks will be creating the internal structure out of layers of coroplast, and hot gluing/screwing them to gether. Cutting so much plastic with a knife was a real pain, so I went to harbor frieght and tool and bought a cheep hot knife. Wow, so much better. Cuts plastic like a a hot something or other through some kind of dairy product.

Latest brain storm is going to be putting 45 watts of solar pannels on top of the engine pods to keep the battery for the night running lights charged. Also have the parts for a 200mw green "Phaser" .

[PhoenixFemmeFatale]

Wow! Your project is looking great! Is it completely enclosed? I couldn't tell from the pics... If it is, are you worried about it being too hot inside?

[Sync]

The doors will be removable, and there may be screens or removable window sections. Haven't got that far yet. Rear panel will probably include partial shade fabric, but have to weigh all this against shelter from dusting. Another possibility is build a fan into the shell. We shall see.

In other shuttle news; It had its first test flight....sort of. High winds this afternoon lifted the shell off the driveway and "flew" it several hundred yards down the street. No damage, good rehearsal for the playa.

[Bounce530]

From experience...Windshields/side windows SUCK! The dust will coat the glass and make it difficult to see through.

[beachlife]

Love the chronicles. looks bad ass. Scotty, beam me up to this mutant vehicle

[Sync]

Over the past few weeks I added the shells of the engine pods, the internal support structure, and cut and framed the main windows. An additional set of windows to give better visibility are going on the front sides. In the process of adding the top fixture, and doing minor fill ins and panels, such as fixing the wheel wells. Should be ready for basic painting undercoat in about a week. Going to wash the cloroplast in acetone, then spray with Krylon fusion satin pewter gray for base.

[trilobyte]

That thing is looking awesome! You may also want to take a look at the Work In Progress thread. I love seeing creative projects come together.

[unjonharley]

bump so I can watch it build.. Great job, can't wait to see..