Cy-Car: "Why we did it that way." Chapter 1

Chapter 9, Mile Post #12 : “Someplace to put your feet” (Click here to read Chapter 8.)

Start Date 11-10-08

Once the main frame and floor supports were installed we began to get serious about beginning the fiberglass construction. The Floor Board parts were the first items to tackle. The total number of floor sections would consist of:
1 Cockpit front left, driver side
2 Cockpit front right, passenger side
3 Transmission tunnel (“Doghouse”), Toyota 5 speed
4 Propeller shaft tunnel
5 Cockpit rear, left driver side, reservoir cover
6 Cockpit rear, right passenger side, electrical area cover
7 Rear wall, behind seats, storage area

These seven parts are designed to allow easy access to components and systems while remaining water tight (road splash) and light weight. It took a number of discussions to decide if the floor boards were to be fiberglass or metal. Fiberglass was the choice if we wanted to give the driver and passenger the maximum space in the foot well areas and incorporate creature features. Simple metal covers would not have been so simple because there were lots of close fitting problems to overcome. Fiberglass was also a good choice for rapid production and finish.

When we were at the SEMA show in early November we meet with a number of carpet and rubber mat vendors. There were some great processes on display from molded rubber to molded carpet. The molding process would give great comfort and the ability to match colors and style of the finish paint work. The other advantage was that when we were done with the floor panel molds the same shaped molds can be given to the carpet or rubber vendors to create form fitting interiors for our car.

A wide search was under taken to find a fiberglass “specialist”, and then we went next door to the fabrication shop and ask our friend Gary Resser to undertake the project. Gary had been watching the progress of the car construction and was waiting for the chance to get involved. We no more than got the words out of our mouth “Gary do you want to ……” and he was underway. The first three items were being fitted the next day and we saw at once that he was a good choice and this was the way to go.

Here is “Quite Gary” at work on the first floor board mold. I think it is for the passenger side.

Gary needed to make the molds so that the body could be fitted onto the frame rails first and the floor board units fitted into place after. Due to the tight fit in many places Gary began to make the molds with only ½” clearance between the mold and items like the transmission and clutch housing.

This is the completed Driver’s side front floor board. I know that there’s a little more work to do, but I won’t tell what it is.

The most difficult item was the “Doghouse”. In these photos you will see that the Doghouse looks square cornered, but once the finished parts are pulled from the molds you will see the corners will be rounded and smoothed out. The finished parts will able to be removed from the car with a Phillips screwdriver in just minutes. This simple removal will give good access to items that may need repair and or removal.


Beginning the Doghouse mold on the left side.	Doghouse right.

This view shows the Doghouse forward section up and over the transmission. A small section is yet to be added to cover at the rear of the transmission and shift tower. Notice the “square” corners which will be rounded off in production.

A number of electronic items are intended to be installed into the Doghouse such as:
1 Cell phone holder
2 GPS
3 Satellite radio
4 Computer mount
5 Drink holders (I know that’s not electronic)
6 Many etcetera
How the electronic accessories are to be installed will be shown and discussed later.

There will more discussion and photos about fiberglass and the parts made of this process in future chapters. Stay tuned. - Carl L. Myers

Click here to read Chapter 10.