Casale Design Custom S2000 Mugen Widebody

Here is my story of the Casale Design Custom Mugen Widebody built for Rywire Motorsport Electronics and ultimately for the owner: Angel Ramos! From Sketches, to clay, to one off FRP molding, to SEMA CRUNCH to final product at the Toyo Treadpass SEMA 2017!

angel ramos s2000 js racing

^Photo above by Joey @Stickydiljoe, showing Angel’s car in the last state (as far as I know, there may have been an updated version since this). Clad in J’s Racing parts, with custom rear quarter panels, and TE37 wheels by Rays.

sketches

After finishing Big Mike’s Honda Prelude, I think Angel felt that it was time to get his car ready for the chopping block haha. Angel got in contact with me about working on the car and he wasn’t really sure what he wanted. He knew he wanted go to Mugen, and possibly some fender flares of some sort. You can see above that there was a phase of rivet-less flares with livery. In the end the idea of a seamless OEM-esque Mugen Widebody was in store for the S2000.

s2k mugen final

^This rendering above was my final proposal for the car’s exterior before getting started on the real thing.. Volk ZE40, custom side skirts, custom Mugen 3 piece wing etc.

fab_0

First things first, I needed to remove the existing bodywork from the car. So drill, hacksaw and Sledge hammer went to town!

random_1

Here is a photo further away showing the car one last time before its transformation.

random_3

After pulling off the custom widened quarters, this is what I was left with!

random_2

After creating a base to start with, I started ‘packing’ the clay onto the quarter to be reshaped.

random_4

Fast forward, here is the car while I was working the clay, scraping and sculpting every surface.

random_5

Here is the rear showing the clay packed onto the rear Mugen bumper ready to be shaped.

random_6

Finalized view of the rear showing the car with the rear bumper extensions and customized Mugen wing.

clay_s2000_1

Here are more finalized images showing the car with the clay sealed before FRP overlays.

clay_s2000_2

Rasping the clay front fender.

clay_s2000_3clay_s2000_4clay_s2000_5

The use of tape, and paper templates help me to quickly transform the clay into form.

clay_s2000_6clay_s2000_7clay_s2000_8clay_s2000_9clay_s2000_10clay_s2000_11clay_s2000_12clay_s2000_13

Some reworking of the spoiler ends before molding them.

clay_s2000_15clay_s2000_16

Clay packed and pushed into shape before using tools. My favorite tool are my hands!

fab_4

FRP Overlay process begins..

fab_17

Overlaying the side skirt forms…

fab_18

Overlay of the rear quarter panels.

fab_15

Everything being overlayed and filled to quickly create some one-off parts.

fab_16fab_12

The Front extensions are coated with a gelcoat topcoat.

fab_6

Rear bumper FRP overlay.

fab_1

Rear bumper Gelcoat topcoating.

fab_14

Rear Quarter blocking…

fab_11

The Parts are then pulled off the car to remoive the clay. Note how the skirt was cut to get ready for the seam line / flange (mounting surface.

fab_10

Tapping Screws drilled for alignment for when this piece gets bonded to the front fender.

fab_13

All the clay has been removed!

fab_9

More blocking of the panels.

fab_8

Front extension overlay that has been added to the front bumper and reinforced from the back.

fab_7fab_3

side skirt overlay being molded also from the backside to create flanges and structure.

fab_2

Bottom portion of the front fenders has been re-worked and glassed to allow for a seamline, side skirt mounting.

fab_5

Photo from the bodyshop after being painted, this is showing the rear spoiler ends being finished with a bolt on type application.

Below: Finished photos at the SEMA show. Things still need to be adjusted to Angel’s liking, but overall I think it turned out well due to the very tight timeframe.

109_edited124_edited126_edited131_edited133_edited121_edited118_edited125_edited111_edited113_edited130_edited115_edited

Advertisements

Leave a Reply

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out / Change )

Twitter picture

You are commenting using your Twitter account. Log Out / Change )

Facebook photo

You are commenting using your Facebook account. Log Out / Change )

Google+ photo

You are commenting using your Google+ account. Log Out / Change )

Connecting to %s