Topic jumping again. Here are a couple of pics of our car in the initial construction stages. Like most teams last year, we did not have a heck of a lot of time to make our car, so we chose a very quick (and inexpensive) method. The template was made and cut out, and the shape transferred onto 2 pieces of 3/4″ “baltic birch type” plywood (2′ X 8′). The shapes were cut out producing 2 identical parts. One would be the base, and one would be the substructure of the top. Sides were cut from 1/8″ luan plywood, often sold as “door skins”. The base plywood was laid on a flat floor and the sides were epoxied and stapled to the plywood edge. The top had access areas cut out and then similarly glued and stapled to the top edge of the sides. A strip of fiberglass tape was epoxied to where the sides joined the top and base. You can see me doing that in the pictures. When the epoxy cured the resulting structure was quite stiff.