07x08 - Once In A Lifetime

[bunniefuu]

I think we need
some sort of plasma ray

so we don't have
to run tires

and just build a hovercraft.

Dave: We're working on
the very first of its kind

at kindig-it design --

a concept production
vehicle.

Alright.
Let's do it.

It's brand new,

but we're cutting it apart.

What we don't want to do
is build a plug car,

send it up,
have the mold pulled off,

and then we find out
the plug car was twisted,

and then every one of our cars
are gonna be that way.

Whoa!

[ sobs ]

I like to smash his fingers!
Smash his fingers!

[ sighs ] what am I going to do
with this guy?

Dave: Clean...

Custom...

Bitchin'.

my name is dave kindig.

Designing and building custom
cars is my life's passion.

With the best mechanics,
technicians, and fabricators

in the business,
quality is our only focus.

We build bitchin' rides.

-- Captions by vitac --
www.Vitac.Com

captions paid for by
discovery communications

I've always wanted to build
a one-off car

that I could do a series of them

and have them all very special
for individual clients.

Perfect example -- the very
first year of corvette, 1953.

I've always been
a huge fan of that car.

Doing my little twist to it,
though,

I think it's going
to be over the top bitchin'.

So, my plan today
is to try and create

a retro-styled modern classic
of a corvette.

Now, the very first year
of the corvette was 1953,

and this, in particular,
body style of corvette

is actually my very favorite

because it has a lot
of european twists,

with the domed headlights,
the sweeps of the body.

It just has a really,
really cool look,

and I've got an idea
of how to make this work.

If you look at the overall
height of the body

and the front,
basically the body

seems to get larger in the front
than it is in the rear,

and one of the common problems
with this car

also that we're going to
try and fix

is the fact that you really
can't sit in the car

if you're taller
than 5'5".

So, a couple of things
I think I'm going to do --

we will actually take

three inches in the front

out to zero.

I want to increase
the size of the wheels,

and I'm really thinking

about raising the wheels wheels
up in that bottom line.

Another thing -- we really want
to open up that interior.

I think if we were even to
increase the length of the door,

but not the wheel base
by three or four inches,

I think we'd be
in really good shape.

So now, a normal sized person
can sit in the car.

With that, kids,

let's get our magic
scissors and start cutting.

but that is slick.

I think what I'll do is go ahead
and draw it.

The color combination
I'm putting on this one

is just so I can kind of see
what the shape of the car is.

Just getting an idea
of quick color,

shows off the shape of the car,

and I'm really liking what I'm
seeing here.

With this concept,
basically, we're wrapped,

and I really think that
the car looks great,

and more so,
I think that I'm convinced

that this will be a great car.

I think the next thing
I'm going to do

is I'm gonna call my buddy
jerry up a corvette image

and see if I can get some parts
and slap one of these together

and start chopping it up.

I'm digging it.

This one's going to be
a really good mix of old and new

or modern and classic

to really come up with something
that's going to be awesome

as a first turnkey
kindig-it design car.

Alright.

So, it is a 1953 corvette,

but I've moved
a lot of stuff around.

I'm kind of inspired, man.

I think this is going to be
really a dope car.

Remember the last time
you were inspired?

Yeah, I know.
It was great.

Sounds like a lot of work
for us.

Yeah, it was a lot of work
for us last time.

[ laughs ]

well, now, remember
what I always say --

if it was easy,
everybody would do it

and then it just wouldn't
be that cool.

Right?
I get it. I get it.

I've got a body coming in,

but I want to build more
than just one of these.

So, this first car,
let's chop it up.

Let's do all the changes
that we want to do.

Let's make it perfect,
and let's pull molds off of it

and we'll
produce these cars.

How many are you
thinking about making?

Well, I actually have
a couple of guys

who are already interested
in the first two,

so -- and I think
I'll have to have number three.

So, three to start.

I think making a concept car

out of a c-1 or c-1s
is amazing.

Do I think we have time
to do it right now? No.

Sounds like a lot of work.

Sounds like he wants us
to build him a car.

[ laughs ]

I really love the idea of
a one-off concept

kindig vehicle.

If it's completely custom,

it's something
that's not on the road,

something that only we build,
and we build awesome cars.

This is like
that next step above.

I'm thinking right now,
mini cooper headlights,

and I've actually got a set
that's been kicking around

that we can just try on there,
see if it's going to work.

Is this longer here?

No. I'm taking three inches
from here to zero.

I'm going to wedge
that whole car.

That lowers the rear section
and it lowers the nose,

even though I'm gonna keep
the nose the stock height.

What about the compartment?
I mean, these aren't big cars.

Is a normal guy, like, my size
going to fit,

or is this only
for your size?

Well, you're only, like, what?
Two inches taller than me?

Okay, whatever.

So, my point
is we're opening up the cab

and I'm figuring probably

we'll get a better idea
once we look at it.

But usually, about a four-inch
stretch. The cabinet is --

like the '62.
Exactly.

But what I'm going to do, too,
is those doors are so short,

we have plenty of room
back here.

Let's just stretch the door
and make it look

proportionate to the car.

Okay.
You know what I mean?

I don't know if I've ever heard
of another hot rod shop

doing a custom concept

and bringing in a production
as multiple cars.

So, I mean, that's something
unique in itself.

What kind of power plants
are you thinking?

Just a variety?

Basically, sky's the limit.
We can do whatever we want.

Build your own car,
pick your motor.

And I want each one
very unique.

Custom colors --
we'll develop those.

Themes for
interior, exterior.

Really, when you start building
the first one,

the second one
is right next to it.

After you've done
those two,

the third one pretty much
builds itself.

Isn't that the one
that dave wanted?

The third one?
That's right.

You can build it
yourself, then.

If it pretty much
builds itself.

Well --
[ laughs ]

you know what?

[ laughter ]

first thing's first for these
concept corvettes --

we need to have it
on a perfect foundation.

That's why the roadster shop's
building us a chassis,

a spec chassis, to be exact.

The really cool thing about
these roadster shop spec chassis

is they're actually designed
to fit on a c-1 corvette,

which is the first series.

Well, much like
any kindig-it design car,

it's a mix of the old
and the new.

So, a c-1 corvette from 1953,

but with all modern suspension
out of a c-6 corvette

from the early 2000s.

Not a bad gig.

alright, rob, we'll just throw
it at this spot

right here for a minute.

[ whistles ]

this is a brand-new
c-1 suspect chassis.

What's really trick on these
is we've got all c-7 suspension,

the front rear
spindles, a-arms,

all of that's off
of a c-7 corvette,

so it's all factory.
Really kick-butt stuff.

What's going to be really cool

is we've got rid
of the trans axle

and it now has
a standard center section.

This is basically a dana 60.

Whoo!
This is pretty.

Sucks.

Come on.
It's not even a volkswagen.

You have no room
to complain at all.

You have a paycheck coming.

Man: So, this is what
we're starting with,

to build the prototype

for the new kindig
'53 corvette.

Alright.
Let's do it.

We are starting with
a 1953 corvette,

so I need every body panel
that would create that,

and then I'm going
to glue it together

and then we're going to
cut it apart.

Where are
we going?

And there's going to be a ton
of modifications

to this stock body.

The very first thing
that we need to do

with our concept-style
corvette is chop it up.

some of the big changes
and the common things

that were wrong
with the '53 corvette

is nobody over
five and a half feet

actually fits in the car.

So, we're going to add
four and a half inches

of length to the cabin.

We're also going to drop
the seats down four inches

between the frame rails.

This is going to allow a much
taller person to sit in the car

and be very comfortable.

We're going to cut off whatever
we need to to get this body

fitting on the chassis
to begin with,

but at the end of the day,

we're going to build
an entirely new floor.

The idea on this concept car

is to not stretch
the wheel base,

but to rather
just stretch the door.

This will give
a more proportionate

look to the door itself

and also make it easier
to get in and out of.

okay, guys, well,
thanks for coming over.

The idea here is
get a game plan.

So, a couple of things
that definitely need to happen.

I sat in the car
the other day.

It's poobahs
unless I'm laid way, way down.

So, we need about a four-inch
drop in the seat pans.

We've got enough length
in the car now

to where it's going
to be comfortable.

We just need to get
the height right.

We have a fixed driveline
that doesn't move

because it's independent.

So, we can put
the exhaust underneath.

We're going to definitely
have to find somewhere tricky

to put some...

Mufflers.
...Some mufflers.

The fuel tank's now
going to go on the back

that will's
going to develop.

We'll figure out how many
gallons we can get in there.

Well, and I figured it out with
just the space that we have,

and depending on
how wide you make it,

it's anywhere from 16
to 24 gallons already.

Yeah.
And without too many mods.

I think 16
being the minimum

would probably be the best.
Yeah.

I mean, if you think about it,
if you keep your foot out of it,

you're going to get over 22
miles to the gallon at least.

-Right? 24?
-20 miles a gallon.

So, as soon as we get the wheels
and tires back

from getting mounted,

what I want to do
is set the wheel in place.

Let's get a marking. Let's go
ahead and open the wheel wells

so that we know where
the stance of the car is.

I think it's important also
at that point that we go ahead

and get the mockup
done on the ground

so we can actually see the car
at the stance

with the wheels
and everything else.

What we don't want to do
is build a plug car,

send it up,
have the mold pulled off,

and then we find out
the plug car was twisted

or has a funny left
or right deal,

and then every one of our cars
are going to be that way.

So, we got to make sure
that it's spot on.

Looks good.
See you next Friday.

See you next Friday.

Think we can have it done
next Friday?

No, I'm just leaving
until next Friday.

What?

Since kevin apparently is going
to take the next week off,

I'm going to get will
to modify this chassis.

Will: We were super hoping
that this spec chassis

was going to just be perfect
for everything.

On paper, it looks great.
Proof is in the pudding.

You got to get it
in front of you

and then make the mods to it
to really make it happen.

It's brand-new,
but we're cutting it apart.

We needed to make some room

so we could put the seat pan
down inside the chassis.

Basically,
the bottom of the seat will be

at the bottom of the chassis

instead of the top
of the chassis.

My goal today is to get this
outer rail moved out,

move this cross member
back to this juncture,

move these in-board.

So then, all of a sudden,
you'll see

we'll have a big pocket here
for your bum to sit down in.

we don't want to cut away
too much material.

So ultimately, I'm going to move
some of the material out-board,

some of the material
in-board,

some of the material forward,

but we're going to keep
this chassis strong.

with all these mods made
to this support beam,

I just need to weld it
back on the chassis.

after a lot of welding,

the chassis
is still the right shape.

New wheels for the mock up
on the corvette are here,

so we're going to
check them out.

Give them a little test fit
before we send it over

to get the tires put on them.

And these are 22s?
This is a 22x12.

If we can get it out.
If we can...

Come on, baby.

Why is it so stuck?

I don't know.
'cause it's a 22.

It's 22-inch wheel
in a 20-inch box.

[ chuckles ]
I'm guessing.

You know, I love
having will a part of this team.

He is so sharp. He is
a big part of it and I love him.

I think we need some sort of
plasma ray

so we don't have
to run tires.

But I think he's been
in the shop too long.

I think that maybe the fumes
are getting to him.

And just
build a hovercraft.

we're creating a plug car
to pull molds off of

for our 1953
concept-style corvettes,

and since I'm the designer,

I can choose whatever size wheel
I want to, and I'm going big.

I think we need some sort of
plasma ray

so we don't have to run tires,
and just build a hovercraft.

You know I'm going to
start drug testing

next month, right?
Aw, man.

[ laughs ]
it opens your mind. What?

Like I need to be on drugs
to come up

with stuff like that.

Are you good
with that thing?

I don't know. Am I?

You might be all right.
Are you good with it?

That's the
better question.

We're not going
to find out.

Don't want to
get dirty, huh?

Well, I don't
mind getting dirty.

Look.

Aw.
Look at my shoes.

That's so sad.
But I'm not getting itchy.

Not today.
I didn't really plan for it.

I don't
have a scuba suit.

Does "not today" mean at some
point in the future you are?

I'm going to definitely
at some point --

I'm going to get itchy
on this car with you,

and it'll be like
a brotherhood of itchiness.

Okay.
I'm waiting for that day.

Okay, don't
hold your breath.

I'm not planning
on it.

oh, geez. Those are heavy.
Yeah.

Solid stock.

Dave: Those are pretty cool.
That's going to be sick.

Hey, you know what?
To answer your question --

you aren't bad
with that electric thing.

Jason: I've had a few hours
behind it.

With the wheels
mocked up on the car now,

it's time for will
to get after

building that floor
on the chassis.

Will: I've been playing
on the computer, designing up

as much of this floor as I could
possibly, you know, get,

trying to pay attention to,
you know,

the space from the frame
to the floor,

room in the tunnel.

Yesterday, I cut all the panels,
and I'm bending them,

fitting some pieces.

So essentially,
what I've come up with

is this giant puzzle

that's going to be a buck
for our fiberglass floor.

The trick is to get it
very seamless.

So, all of a sudden,
we have a whole complete floor

and the body panels
can drop right on here.

It'll be really easy for them
to build the body off of it.

Used as many times
as we need to.

Hopefully, we'll sell a zillion
of these cars.

now, I think I'm going to do
the same thing,

add a couple little pieces,
mainly spacers,

so that I know that everything's
running really true.

What I'm after is
three-and-three-quarter radius.

What I have is totally wrong.

So, usually when you get
the stuff mapped out,

you don't want
to make a mistake.

If you have one,
it can lead into multiple.

What a dummy.

What I have is
three-and-a-half-inch diameter,

so that's totally wrong.

So, let's go see
how it looks on the car

and what I'm going to have to do

to remedy my over-tight
bend that I just put in there.

You really don't want
to move ahead

if you know you've
got something wrong.

It causes you to just do
everything essentially wrong.

We can do that easy enough.

now, look.

We're kind of trapped
between a rock and a hard place.

I have two pieces
that go right here,

so let's see how well
they're going to fit.

I had this whole thing
mapped out,

so if I can't get
this piece to work,

I'm going to have to re-bend
this whole thing.

I think we're okay with the
radius and diameter situation.

I was able to get everything
figured out,

but there's one last change
I want to make to this floor.

We need it to dip down
where the seats go.

with the seats being dropped
down four inches,

somebody taller can fit in this

without their head
sticking out of it,

like the poobahs.

The floor looks great,

but I'm still a little bit
worried about will.

[ high-pitched voice ]
we're gonna have a class today

on how to beat
your head against the wall.

[ laughs ]

[ normal voice ] so, I have to
build a set of tubs

for the '53 vette.

It's kind of cool

because I basically built them
in the computer first,

and the reason why I built
this buck is because

there's a pretty specific shape,
big radius on this inboard side.

Now, I know that
there's going to be

a little bit of adjustment

how it comes
and meets the wheel well.

We're going to get
the majority of it done.

This could just be
straight,

then this has to be shrunk.

It could wrap around the piece.

Then to get this other side,

we're going to go ahead
and throw this on here.

But as this rotates side
to side,

it's going to kind of
follow a circle.

So, one, we're going to do the
cylinder on the english wheel.

Basically a rubber band
around the top dye

so it just pushes
the shape into it.

It'll just make it cylindrical

so that it will wrap all
the way up around this radius.

We don't want any shape
in this section past there.

So, we're going to roll
right up to this.

this is our big shrinker,

and you'll see
it does a hell of a job.

okay. I got this fitting
like I like.

Now what I need to do

is make a top panel,
same radius along here,

then I can trim this in
and weld it right here.

[ high-pitched voice ]
hello. I'm mr. Hammer.

And I like to play
in the puppet show.

And then sometimes, when my
friend mr. Glove is around,

I like to smash his fingers!
Smash his fingers!

[ sighs ] what am I going to
do with this guy?

Dave:
We're working on the very first
of its kind at kindig-it design,

a concept production vehicle.

Will just finished up with the
wheel tubs and the floor.

Will: Alright, cool.

Got these all done,
welded up.

Now I just got to
shove them in.

okay, cool.
There's one.

well, that's cool.

That's awesome.

I need to get this over
to the body side

so they can do their part.

Dave:
Hey, so it looks like you're
putting a car together here.

I was trying.
You got it over

into the next stage, huh?

Yeah.

It's looking
pretty good there.

Got the glue flange right here
for the tub to go in.

This will give us adjustability
again to be able to put it

wherever it needs to go.

I tried to make
the floor piece,

like, kind of as big
and as complete as possible.

We need this very first car
to be perfect

because we're pulling
molds off of this car.

He doesn't have to pull
a mold off of this.

This is the mold.

Yes.
It's going to be awesome.

Yeah.
Everybody was kind of confused

and scratching their heads
wondering what I was doing.

Well, you could have
done it either way.

But I think, you know --
this is way better.

I think this is way.
My way was way better.

It's rare, but true.

[ laughs ]
I'm kidding you.

Hey, I'm kidding
you, bro.

Okay, I've had
enough of you.

Yeah, no kidding, right?
Okay.

Alright.
That's rad.

Good job.
Thank you.

We've already
stretched the cabin,

lowered the seats, and added
more room for bigger wheels,

and now howard's in charge
of addressing the trunk,

the wheel wells,
the engine bay --

pretty much the whole car.

Basically, because of all
the modifications we did,

I'm working on closing
the trunk area.

This is the gas tank
surround.

The gas tank
will drop down into here.

We have these drop-down panels,
and it all gets sealed.

That way, you won't
have exhaust fumes

and stuff coming up
into the car.

dave: On this car, it's
all about making sure

that the surfaces are smooth

and can be replicated
with a great mold.

That means we're using anything
we need to --

cardboard, bondo,
fiberglass, steel, aluminum.

You name it, we're using it.

Heck, we might even get the


kevin: You know, ever since
the beginning of time,

chevrolet built these cars
out of fiberglass.

Corvettes
were built from fiberglass

because in the very first one,
it was a performance car

and they were looking
to save weight.

It's not my favorite thing
or substrate to work with,

but it has its advantages.

It's light.
It's pretty strong.

I don't know if I'd want
to get in a car accident.

And howard loves it.

dave: We've already completed
a ton of design changes

on this particular corvette.

But we're not even close
to being done yet.

Greg is going to scan
the entire car

so we have digital information

so that we can develop
the trim around the doors,

the windshield frame,
headlights and taillights

and some other parts.

greg: Replicate where
the headlights are going to be.

hey, guys. How's the c-1
coming along? Good?

Yeah, it's coming
awesome.

Greg's got it
pretty much all scanned in,

so we'll have
the digital information.

So we're ready
to start moving on

to molds to get some fiberglass
bodies coming.

Far out.

So, I'm glad
you brought that up, actually.

Something I wanted
to talk to you guys about.

I have a couple of friends.
Do you remember doug graf?

Oh, yeah,
from crc?

You know, all corvettes
were made out of fiberglass.

But what makes a kindig-it
design corvette better?

I think I know
where this is going.

[ laughs ]

I think I'm going to have
these bodies done

out of carbon fiber.

I don't know why you didn't
do that in the first place.

Well, I was thinking, you know,
doing the press molds and stuff.

But to be honest with you,
I think by the time the cost

is all factored in and that
and the fact that carbon fiber

is just that much cooler
and it's lightweight, strong,

and I think
it's a hell of a sales point,

I think we're going to do these
things out of carbon fiber.

That sounds
like a lot more work,

and we thought
we were done.

Big time.
[ laughs ]

but you're all
bad news.

Wait until these guys
see what I'm seeing.

Guys. Fellas.

It's our first kindig-it design
full carbon-fiber turnkey car.

Yeah, that's not
what I'm seeing. Not even close.

Okay, can you please talk them
into doing the molds?

I don't think
it's that hard. Really?

"I don't think
it's that hard."

I want to move
through this project.

I want to keep going.

I was just about
to go on vacation.

Don't do that.
Me, too.

Don't either one of you
do that.

Let's picture this.
Let's picture this.

A white sandy beach

with sea turtles.
And a carbon fiber corvette.

No, no,
there's no corvettes there

'cause there's no work there.
It's the beach.

With the boats.
With the boats.

Is there room on
that boat for me?

There's a lady
that comes up in a bikini

and brings me piña coladas
all day long.

[ both laugh ]

that's really hard to beat.

But I am really excited about
these bodies, though, guys.

We're going to go.
We need to go to the internet.

We're going to get plane tickets
to bora bora.

They're making molds
in bora bora?

You're not invited.

Doug and austin
will be here next week.

-Bye.
-Uh-huh.

Put the bora bora
up your butt.

Regardless of what the guys
in the shop think,

carbon fiber is definitely going
to put us to another level,

and here comes the experts
to show us how.

Doug, here we go.

Austin,
what do you think?

Austin: Beautiful.
Absolutely gorgeous.

We're here with doug in austin,
and doug graf

is the owner of crc.

I think we've got you guys
a pretty good plug car,

but I'm glad you guys
came down here to look at it.

Doug graf and his right
hand man austin are here

to show us exactly how to make
the perfect carbon fiber mold

for the perfect
carbon fiber parts.

These guys have been doing it
for a long time,

so I'm really interested
to find out

how it's done and do it right.

Austin:
Our goal is to come in here

and help you to fashion
the splits on the molds.

I know you want to make
a one-piece mold for this body,

which will be incredible.

Little bit of
an extra challenge,

but it's that extra distance

that you usually go
on your cars.

We're going to love
working with you.

Yeah. Well, and I think
we're going to love the fact

that the car is not
another fiberglass...

Yeah.
...Corvette. It's carbon fiber.

For those of you who are
corvette aficionados

and purists,

you might want
to turn your head.

My intention of this car
is to not necessarily have

any carbon fiber
clear coated.

So, let's talk
about the mold.

Basically,
everything on this car

has to release almost like
a stack of dixie cups.

You want to be able
to pull the cups off,

and you'll have your piece,

which would be
the next cup down.

So what is the first thing
that we need

to do on our mold making?

We're going to need to start

finding our partition lines
for the mold.

Obviously, we can't make this
in one large piece.

You'll never get the part
out of the mold.

We're going to need
to divide this up

into a number of sections.

The car will come out
in one piece,

but the mold will have
to be separated.

When we make our parts,
we need a vacuum flange.

We need an
outside-the-part perimeter,

and then we adhere a solid bag,
put a vacuum port on it,

take all the air out of it,
which creates about 12 pounds

per square inch of vacuum
pressure on those parts.

That's why we get
such an incredible part,

and it's only
seventy-thousandths

of an inch thick.

That's awesome.

Building a carbon fiber mold

takes special attention
to detail

to make sure
all of the parts line up.

Austin:
Yeah, it's just going to --

I think it'll just
go like clockwork.

I can't wait. Well, we're ready
to get started immediately.

So, let's pull
some molds.

Sounds good. I'm ready.
Awesome.

Looking very forward to
getting it done.

Awesome. Thanks again.
Welcome aboard, sir.

Thank you.
Thank you.

Before we can build the molds,
there's still one thing

that we have to do,
no matter what,

even if I don't want to do it.

[ "taps" playing ]

[ sobs ]

dave: We just met with
doug and austin,

the professionals that do this
carbon fiber stuff,

and we're ready
to start pulling molds.

really, the car's charm is
to have these cool little fins

on the rear quarter panels,
and to be honest with you,

I'm a little sad
to see them being chopped off.

[ sobs ]

it sucks in the moment,
but it's important

that the car
comes out of the mold.

I'd like a moment of silence
for the fins.

[ "taps" plays ]

that'll do.

Every last one
of these panels

has been dialed in
and is flawless.

Now it's time to start
pulling some molds.

The smaller molds, such as the
inside and outside of the doors,

the trunk, and the hood, they're
going to be a lot easier to do.

So, we're going to go out
and start on those

and get a hang of
how to build a proper mold.

This is all tooling
mold fiberglass,

so that can actually
take higher temps.

One of the big things that we
need to start with, though,

is this black epoxy resin.

It's official name is
pt1540.

Pain in the a*s.

Once we get
this pain in the a*s --

I'm sorry -- black epoxy
resin down,

then it's time for jason
to figure out a pattern

to put all of
the fiberglass layers down.

jason: So, we got a ton
of molds to make.

We've made a few of them,

but we're using
this fiberglass cloth.

It's a little bit better
for what we're doing to build

the molds 'cause we want the
molds to be super strong

and structural.

We want to do this
concept car justice,

and that means we got
to make the perfect mold

and keep them very structural.

We've got the deck lid
on the outside done.

Now we have to do
the bottom side.

So we've got the structure
for the mold in place.

Now, all we're going to do
is glue all of the structure

together
to hold it where we want,

and then we should be able to
pop the mold soon as that dries.

You can tell how much fun
it is because the first day

when we started this,
everybody was all gung-h*.

We had how many people
over here? Like...

Ten people all excited,
wanted to help,

and now it's
me and maddie.

[ laughs ]

takes forever. I mean, if you
did one part steady,

it'd probably take
two or three days

per part on the car.

It'll be fun when the project's
done, just not right now.

the molds are now
completely dry

and ready for a b-stage cure,

but first, we've got to try
and get the part out of them.

Popping the molds is my favorite
part of the whole process

because everything else is
just wet and sticky and messy,

but then popping that piece
off, hearing it crack loose,

it's just so satisfying to see
an awesome, perfect lay-up.

Some parts are really easy
to pop loose

because they're not
very contoured.

Other ones are
a little bit tricky.

When these molds don't pop out
the way they're supposed to,

it gets really stressful.

The idea is to not damage
any of the molds.

I mean, of course, you may have
a small chip or a crack.

If we find any major problems,
that could be bad.

This would put us right back
to step one of mold building.

Sucks to do it the first time.

It would really suck
to do it a second time.

Man: Damn!

Greg: I finished printing
the last pieces

of my windshield frame

that I've been designing
for the '53 corvette.

The pieces in the printer
are actually super hot.

So when I pull them out,
I need the gloves

so I don't burn my hands.

This thing's basically an oven.

I had to print them
of crazy standing up like that

just because they're so big.

The windshield frame for the car

is, you know,
the width of the car

and then it's about a foot tall.

So, what I did was I chopped
it into sections in the computer

and then once
they're all cleaned up,

I can glue them all together
and then we can get an idea

of what the windshield frame
will look like.

The final piece is going to be
cast out of bronze

and then it'll be chrome plated.

I showed dave in the computer
what it looked like

and he likes the way it's going.

But having it in real life on
the car is just --

it's invaluable.

I need to break out
the support materials.

I got these things
all cleaned up,

and the way they go together,

you can see right here,
I cut these little pins

and put them in
and glued them in.

With this last one,

we got to do both sides
at the same time,

so I'm having eric help me
with this last little bit.

Okay. I'm started.

This stuff set
so quick.

Just makes me
so anxious every time

I use this kind of glue.

This is looking really good,
and it all fit together

really nicely.

It seems really strong.

I think
this worked out really well.

Jason: You got the deck lid
on the outside done.

Now we have to do
the bottom side.

When these molds don't pop out
the way they're supposed to,

it gets really stressful.

Some parts are really easy
to pop loose

because they're not
very contoured.

Other ones are
a little bit tricky.

There it goes.

Pulled the old boot out
to make the molds.

Now we have
the inner structure mold

so we can lay
the carbon down.

It looks awesome.
Just got to clean this up.

We've completed the plug
for our concept style car

after months and months of work,

but the plug is not
the final part of the car.

This is just the plug that will
create the perfect molds

off the perfect plug.

And so far, the molds
are looking pretty good.

We're getting really good
at making molds

for the smaller pieces,

but the big body,
itt's coming up next.

Jason: We're starting to put
the body mold separators

on the front of the car
and the rear.

If we can build four or five,
six different molds,

but then when we pull them off,
we have one solid piece

so we can not have any seams
or anything on it,

so we're going to
split it down the center

and then down
the top of each fender

so we can start glassing them in

and getting them
ready to lay up,

top it all off at one time.

That's when it'll all
be worth it.

But until then,
fiberglass blows.

Maddie: I'm filling in
all the cracks with clay

so that when we put the hardware
and fiberglass on,

it won't leak through.

Then we'll good edges
for each side of the mold.

Jason: Maddie's really good
at the clay stuff.

She gets it really smooth.
So we can seam all the cracks.

Definitely important
to get every step right.

If you forget to seal off
a piece with clay,

then you have an extra extension
on the mold

that you then have in
every single piece.

If you forget the wax,
you ain't gonna pop the mold.

If you forget the gel coat,

it's not going
to pop out. Great.

Definitely don't want
to miss any steps.

It's not just one simple part
you can redo.

It's the entire skin
and body

and structure interior
of the car.

we're ready to start
laying the glass

on the bottom side
of the roll pan.

This is going
to be upside down.

Gonna have one person
on the floor,

which is me.

I lost the bet.

Yeah, I don't have to be
under the car today.

[ laughs ]

maddie's going to
hand them down to me,

and then we'll just put them
on upside down

and enjoy the potential rainfall
of resin drips.

It's definitely going to be
running down my hands.

So, I'm just trying
to minimize the inevitable.

Yep.
Ready to roll.

we're almost there.

I see the light
at the end of the tunnel.

The crew is making
great progress on these molds

for the c-1
carbon fiber corvettes.

We've already got the top
and the front and rear made,

but now it's time
to tackle the sides.

So, the car's coming along
really well.

This is by far --
by far, far --

the biggest piece of fiberglass
I've ever made.

We got the entire top
half of the car in glass.

So, what we're doing now

is maddie and I are
chasing the sides.

We're getting them prepped.

Want to get them laid up so we
can get the rest of the mold,

then we can pop it apart,

take everything off.

So, right now,
we're doing the doors.

We've got one side done.

I was able to crawl in there
and do that side.

Maddie's got to do
this side

because I'm not skinny enough
to get out the back of the car.

So, she gets to be the one who
gets locked inside the car.

So, we're going to put on
this side door flange

to lay up the car,
drill it in place,

and then start planing it

and getting ready to lay up
the glass

on the sides of the car.

Should go really well.

Just a little claustrophobia
going on.

I don't think so,
but I guess we'll see.

The reason we're putting
these door panel pieces on

is because we want
to make a one-piece mold

is what we're after.

The sides of the car
half a lower rocker,

but because it's got the rocker,

we don't want to have one piece
without a center section.

It has the potential
to bend or bow

and crack in the middle.

And since we're doing
a one piece mold,

we're going to use this
and we're actually going to

lay glass
in and on it

strictly
as a structural support.

'cause everybody does pieces,

but we want it one solid piece

when it comes out
as carbon fiber.

I think this is going to be
easier said than done.

I'll just leave it up to jason.

If you kick your feet
in with the front

at the very bottom of
the panel --

just push it in hard.

Don't worry about
bending the metal.

If you can put it at the very
bottom of the edge.

There's too much wax.
Give me a second.

-There's too much what?
-Wax. I just keep moving.

Yeah, it's super slippery
in there.

[ maddie laughs ]

can you pull it up
more on the front?

Uh...

Try that.

Probably as close
as we can get.

When you drill,
just drill, like,

just barely above
the bottom of the sheet metal.

That's not holding it
in enough.

I can't hear a word
she's saying.

Sounds like
charlie brown's teacher.

Wah-wah-wah-
wah-wah-wah.

[ chuckles ]
okay, try it.

There you go.

Yeah, that looks good.

Well, my job's over 'cause
that's screwed in place.

I could probably
go to lunch and come back

and she'd never
even know.

I wouldn't really do that.

There's still a lot more
I can help out with.

I'm going to send
the welder in.

Maddie: Okay.
Let's just put one

right in the center
since this is the one

we got crawling
and grind out.

Okay.

perfect.
Okay.

I think that's good.

There was
some stuff.

Okay, come on out.

Oh, that knee's
stuck.

We are making the molds of our
concept styled kindig vettes.

Jason: Right now,
we're doing the doors.

We got one side done.

I was able to crawl
in there and do that side.

Maddie's got to do
this side

because I'm not skinny enough

to get out the back of the car.

I don't think so,
but I guess we'll see.

Not yet.

jason: Perfect.
Okay, come on out.

Oh, that knee
is stuck.

Oh.

Awesome.
That worked out great.

Ugh.

Now we know that maddie
can get in and out of this car,

I got some more bad news for her
after we finish the sidewalls.

You know, you got to do it
one more time

when we take it out.
Wonderful.

Funnest thing all day.

This is just a filler material
to speed up the process.

Well, let's start
cleaning up, cleaning it.

And we fill in
a little bit of gap

that we have with the clay

so we get a perfect,
nice, flat mold.

After getting the door section
ready for the vacuum bags,

maddie's going to
put in a flange

around the wheel well opening

so they have somewhere
to tape off the bags.

Next, it's all hands on deck
for the side molds.

Yeah, I ain't
doing this alone.

I'm bringing
them down with me.

We want to make sure
that the sides

are structured up enough
to make sure

that they can withstand
the vacuum pressure

of a vacuum mold.

The mandatory
amount of fiberglass

to make sure
that these are solid

and not going to twist
or move is very important.

-This is layer two of 11.
-This is layer one.

Well, you guys are behind us.
Trying to make you look good.

[ laughs ]

man:
Hey, coming to help?

No.

After this square, about


Dave:
The idea behind doing smaller
pieces of fiberglass

on this big mold

is so that it's easier to handle
and manage,

and of course,
by crosshatching going straight

and then 45 really adds
a lot of strength to it.

A few thousand squares
of fiberglass later,

we're ready for
the backer board.

This is going to add structure

and make sure
that the mold does not twist

and it's able to be set
upside down on a flat surface.

After months and months of work,

this thing is finally ready.
Let's see how it looks.

It's popping day.
We're gonna pop the molds.

Super excited,
super nervous.

Should turn out
really good, though.

Maddie jumped back
in the car.

Maddie: Okay.

I'm gonna hang out here.

Until she gets a couple of
the metal backer boards

that we put in that
are taken off

so we can pop the sides off.

Check out
our first piece.

Whew.

Hopefully it comes off easy,
in one piece, and looks good

because I don't
want to redo it.

Oh, tough guy's here.

If things don't go smoothly,

I'm gonna be
really upset.

there it goes.

Yeah, you can see it.
It's twisting right there.

Pretty sure it's
'cause these lights.

It looks like we have a little
bit of a trap

between the wheel well
and the headlight,

and we need to try
and free this

or break it loose
without breaking the mold.

yeah.

Just don't pull
too hard.

This entire
process has been very tedious

on me and my crew,

but this last part is
going to push us over the edge.

Whoa!

Man:
It's not budging.