The bodywork was made from 1.5mm aircraft plywood with two 6mm plywood formers. The bubble flange was used to position and mark out the plywood sides and also as a template to cut out the top former.
Gluing Bubble Locator
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Gluing Sides & Top Former
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A thin plywood strip was then glued to the inside face of the bodywork, providing a step to locate the bubble.
The mudguards were formed from 1.5mm ply and glued with corner beads and then glued into the main bodywork.
The joints and seams were then sealed with polyester resin. An aluminium tube was fitted to brace the two sides and the mirrors fitted.
VENTILATION
I then had an amazing bit of good fortune finding a 2 for 1 offer on a suitable air intake diffuser.
A glass filled nylon inlet was turned to match the angle of the diffuser and the assembly glued into the nose. The larger end of the diffuser was fitted with a sleeve that would allow an extension to be used to direct the incoming air directly onto the screen.
The bodywork was painted with a small roller and shocking pink vinyl silk emulsion.
This was the colour we used on one of the original school electric cars which I thought made it stand out well.
PAINTING THE SCREEN
The screen was then held in place on the bodywork and an area marked out for sun shading. This was done on the outside with some thin black tape.
This shape was then transferred to the inside using masking tape and that area was painted with silver model paint applied with a small brush.
FINISHING TOUCHES
A pair of bottle cages was fitted and the seat covered with blue camping roll foam.
The numbers were then fitted on the front mudguards and the inside of the screen.
The screen was then taped into place using 25mm black tape.
TESTING
The first test was done at Reading Velodrome but did not last very long. I gradually built the speed up over a few laps and at about 30mph there was a distinct burning rubber smell.
I stopped and had a good look over the machine with Slash, expecting to see one of the front wheels rubbing as the clearances are rather tight. We couldn’t see anything obvious so I went back on the track and built up the speed again but at about 32mph the rear tyre blew and I skidded sideways across the track and came to a very quick halt.
The blowout was caused by a lack of torsional stiffness in the rear wheel support which was easily cured by the addition of triangular brace on each side.
I was very pleased with the initial performance of the trike especially its stability during its sideways skid.
RACING
The first 2 hour race at Castle Combe was a bit tough as I was not very fit but I managed 4th place and averaged 28mph which was actually 30mph for the first hour and 26mph for the second.
As the season progressed, my performances improved as I got fitter and more used to driving the trike. It is a joy to drive on fast twisty circuits and I managed mainly 2nd and 3rd positions during the rest of the 2009 season and ended up 3rd overall.