I took the opportunity of this week's good weather to be able to work outside and make a section that needed the use of a LOT of glue - including a fair bit of superglue. Namely the framework which the bonnet will sit on and to which the exhaust manifold attaches to. If I didn't have the exhaust to worry about, I could've done this much more simply, but as the exhaust is external and only attaches at two points (engine and a bracket on the right hand side of the driver's cab), I had no choice but to create a much more substantial structure.
First step was a comprehensive set of drawings (not shown) to get all the shapes and dimensions down pat. And as has been the case with this right from the get-go, I have to deal with various changes of profile as well. That led to the creation of a lot of individual pieces of card (a mix of cereal packet card and a piece from an old board-backed envelope) that had to be cut out, then slots cut into them before the whole thing just fits together. Fiddly, yet surprisingly simple and effective. And would've been fine as was if I didn't have to deal with that dratted exhaust...
Next, I added the spacers (see above) along the sides, leaving spaces where the exhaust has to go, and I also cut away the section at the roll cage end to make the footwell of the cab / cockpit.
Then it was off outdoors to "fill the holes" as it were, in order to provide a solid section to which to attach the engine "block" and exhaust manifold, as well as add some reinforcing webs wherever needed. A whole lot of 14mm square sections of corrugated card were used for this, although about 2/3 way through I had to switch from superglue to epoxy, as even outside I was having problems - not so much with the fumes given off, but with the allergy side of things. Hey ho, what wouldn't I give for a decent fume cabinet...
Top view
Bottom view
Once this had all set rock hard, then it was the squeaky bum moment - cutting away the bit where the engine would be on the actual car. The bit where you pray things won't fall apart on you as soon as you stick the scissors in... But, mission accomplished, and this is what I ended up with:
Theoretically, I could've left it like that, as under the bodywork, no one would be any the wiser. But in that state it offends my sensibilities, so, on with a top layer, which not only meets the whole aesthetics thing, but also adds to the structural integrity. Plus I tidied and reinforced the edge of the cut out as well. I used 2-part epoxy for this stage, as I needed the wiggle room to allow me to get all the pieces of card lined up correctly.
One thing I discovered is that partially-set epoxy is great for rolling into fine threads and used for filling in gaps, or rolling into balls and poking those into wiggly corners to reinforce them. Although I do still need to sand down the odd rough edge as a result...
And then, onto the nose cone. On the actual car, this is a hollow section, which acts as a "scoop" for the radiator, and while I'm not modelling the radiator, this still has to look right. To make things harder, there's a change of profile in the shape as well, so I had to compromise and build the first part of it integral with the main body so that it wouldn't fall apart. Have to say, this bit was fiddly as I made the "skin" in one piece (well, two if I want to be pedantic, as it's made of two layers of card), creased it and then folded it to create the shape before finally gluing everything in place.
Another piece I have to make at this stage is the air filter, as the actual bodywork fits around it - well, the sides, as the top sits proud of the bodywork. Which means it has to be stuck to this. It's ridiculous how such a small part can take such a long time to make. I started at midnight thinking "oh, this will take me 20 mins, I'll do this before I go to bed" and then, suddenly two hours later...
Didn't take any pics while I was making it, but it's essentially three oval rings of card glued together, plus an additional spacer on one long side, as while the bonnet slopes, the top of the filter sits horizontally. Hence the need to create the angle. The ribs of the filter are made with waxed upholstery twine, wrapped around the rings with the help of a needle just to make things easier, and then glued into place. Then top and bottom added, plus two small glass beads stuck to the top in lieu of the wing nuts that hold the filter closed. Sorry, not the best pic, but with a 2p piece for scale
And then, everything in situ. I've not glued these pieces together yet, simply because I don't quite trust myself to not have made a booboo somewhere along the line. I'll do this once I get to making the bodywork proper. It's more a peace-of-mind thing really...
And a quick preview of how it looks on the chassis. Just because, you know...
I bet it looked good. 
