We learned the effect of compounding overestimation as 100 sheets of XEPS (Styrofoam) arrived today, filling up most of the garage's main room. This should provide us with plenty of foam for manufacturing the shell and fairings for Gato del Sol IV.
This foam will be used to create a male mold, also known as a plug, in the shape of Gato 4's shell. This will be accomplished in two steps. First, we will cut and glue the 2 inch sections of foam together to form the rough shape of the car. Second, we will use a large 5-axis CNC to precisely mill the shape of the car from this block using our 3D CAD model as the reference.
Thanks to Lowe's of N.E. Lexington and their price-match guarantee for helping us to move forward with our new shell-manufacturing process!