Rick Wianecki's velomobile project
Velomobile 6

A project by Rick Wianecki

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Rick Wianecki is building a velomobile. He made many foam models to decide what he wanted the body to look like.
Here's Rick's blueprint for the velomobile. This is not the final plan he used to build the velomobile.

Here's the assembly for the Kingpin suspension units that Rick built for the front wheels of the trike. 
This the the trike frame in it's jig.
Well I have been making progress on the frame for the velomobile. I will be getting together with Waren and starting a page with the complete build.
Each of the front spindles slide in delrin bushings. There is a combination of a spring and a urethane bushing to provide the suspension. Right now I am using a medium rate spring that can be changed once I get the body mounted. The front wheels are 4406 and have drum brakes.
Well I have been working on the Velombile project some more.

I plotted and cut out foam sections for the fairing like I did for the F-n-L (now Attila) streamliner. Here are the section all cut out ready to be assembled.
After about two two hours of assembly.
This picture shows the electric assist trike in font of faring skeleton. The next step is covering the skeleton with strips of 1/2 inch foam to make the faring shell.
I started to add the 1/2 inch foam strips today. I started on the bottom with 3 inch wide strips and worked my way up. when the curvature got tighter I changed to smaller strips.

Here is how it looks with the strips on the back side
I am adding a foam lip where the top section and bottom section meet.
Well I worked on the foam body some more this weekend. It is taking me longer then I expected but it is turning out great.
Here is a view of the body from the left rear, I still need to carve the foam to shape the rear section.
Here is a view from the front. Now it is starting to look like a Velomobile.
Still have a little to do on the right side and a lot of sanding to bring out the final shape. I also need to order some fiberglass cloth and epoxy.
I finished applying the 1/2" foam to the skeleton and then spent several hours sanding to get the shape I wanted.
This is looking at the rear of the body.
Looking from the front. Finalfoamfront_sm.jpg">
Finalwheelopenings_sm.jpg"> One of the front wheel opening
The next thing to do is cover the foam with 2 layers of 9 oz fiberglass cloth. I just happened to get a delivery from UPS.
Well Dave Johnson came by today and we did some more work on the Velo body.
We started out by covering the most of the foam with one layer of 9 oz fiberglas. It was attached with spray glue.
We then cut the second layer of cloth and stacked the pieces and started from the back wetting out the first layer and then adding the second, working toward the front.
After several hours two 9 oz layers on the main part of the body.

Once this cures I will turn the body over and place two layers on the bottom and the inside of the wheel wells.

I will not be enclosing the wheels and have not considered radiusing the back of the wheel wells. I used 3M Super 77 spray glue to assemble most of the shell and skeleton (6 can so far), I also used some hot glue on the inside surfaces, I plan on removing most of the ribs and bulkheads since I am just interested in the shell. I will add a layer of fiberglass on selected surfaces on the inside of the shell.

Well I got to work on the body a little today, I was able to flip it over and get the bottom section ready by precutting the fiberglass cloth. I hope to be able to get it epoxied tomorrow. I will not have any help.

 I have several bags of micro, I may just look for some light weight bondo after I prime with feather fill, not sure we will see how things go.

Finished up the bottom 2-layers of cloth today, did not take all at long. I added some peel ply I had in-stock after the second layer of cloth. Looks like it is going to work great.

Back to the office tomorrow and then work on Atilla next weekend, Progress is going to slow down some.
So when I got home from work tonight, I removed the peel ply from the bottom section of the body.
It came up easy and left a very nice surface that will not need much additional work. Thanks Larry for the tip. Here is a picture of the underside at the nose you can see the difference in the surface between the peel ply side and no peel ply.
I flipped the body over and started to sand the surface There were several areas in the valley of the nose that the fabric bridged. I cut those out and relaid a couple layer of cloth and of course I am using peel ply on the outside.

I have some faring compound that I can mix with the epoxy, or I will look for some light weight bondo to refine the surface on areas I did not use the peel ply.

Today I decided to cut the removable top off and start adding the reinforcing strips to beef up the lip on the top and bottom section.
I first used some 1/8" carbon rods to mark the line that will be cut.
I then use a pull saw and a hacksaw blade to make the cut along the line.
Once the cut was made all around the top separated from the bottom.
Now I will be cutting foam wedges to reinforce the lip around the top and bottom before I add a layer or two of fiberglass to the lip and reinforcement.
Well it has been 4-days since I layed up the top part, with the West System I have not noticed any shrinkage on any of my other epoxy projects. It may have something to do with the foam core or not using any molds or I have been cold curing in the shop at night? It will still be a week or so before I get all the foam reinforcing in place and ready for the epoxy and glass the. I will then put the pieces back together and do the final fit and finish before I remove the internal skeleton and fit the frame. I plan on adding one layer of glass on the inside to seal up the foam after everything in put together.
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