Tuesday, August 17, 2010

THE AUTO SALON COROLLA: STAGE 2 - THE FIRST INCISION

In the first instalment of the build, we take you through the initial steps of how we make the body-kit from scratch.



When a new vehicle model comes out the aftermarket is not far behind it. Tuning companies scramble over one another to flaunt their goodies for the new platform. One of the first modifications that find their way onto the car are styling enhancements.

Some of these body-kits make it into the history books as true improvements, while others are relocated to the “what were they thinking?” category. Either way they are subjected to public scrutiny and everyone has an opinion on how good or bad the kit looks.

So this begs the question of – what would you do? If you could take the aftermarket into your own hands, what crazy conception could you come up with? An opportunity like this is afforded only to select individuals around the world. There are not many people that can say they’ve designed how a car looks. So being the kind of giving people were are, we just had to rectify this.

Auto Salon’s Design & Win competition saw us give a break to talented modifiers. In a chance for people to dream up their dream ride, entrants could sketch, doodle, chop or render their impression of how a car should look. The blank canvas? A 2010 Toyota Corolla.

We were inundated with submissions, but the ultimate winner was Tarek Serougi’s hand sketch of his ultimate Corolla. In the first instalment of the build, we take you through the initial steps of how we make the body-kit from scratch.


The grille of a car is often what sets it apart. Here the factory grille was removed and used as a template for the custom grille. The deep grille gives the Corolla a far more menacing look


Precisely laid masking tape helps line up various axis to ensure symmetry.


An opening was made across the bottom of the standard front bar. This was then inserted with the desired shapes by using a combination of body filler and fibreglass.


No computer-aided diagrams or high tech machining here – just good old fashioned artistry! As the sketch was done by hand, what better way to turn it into reality than by hand?


Despite it being far from completed you can already see the potential


After marking the sections with masking tape...


… the opening in the bar is carefully cut out. We just had to make sure we had a very steady hand.


Yes, it does take a lot of courage to cut into a brand new car. This opening will be the basis of the rear diffuser and exhaust housing.


Hands down, sanding is the most labour intensive part of any body-kit. Be it one completely made from scratch or a fibreglass kit being fitted to a car, they all require a good rub down to ensure the panel lines are perfect.


These shapes will eventually become the plug for the mould. The front bar will come off the car, be painted, coated in wax and with a special resin it will be fibreglassed over to make the mould. Think of it as making a jelly, except we’re making the mould as well!

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