Breadvan_update_051: car design for coachbuilding
From clay model to paper mould
An overview of the coachbuilding work so far. The first step is to sign off the shape of the bodywork in clay. The forms of the model are made based on our design and carefully curated. Design and coachbuilding working in sync to make and fine-tune the clay model. After finishing the clay, the next step is to convert this model into the same exact shape in aluminium. Most noteworthy: the craft of making a bespoke car body will now come into play! Above all it is important volumes, lines and surfaces will be carefully duplicated. Of course the aluminium panels have to exactly match the clay model. Proportions, surfacing and jewellery of this bespoke commission have been delicately refined. None of this sophistication can be lost. Consequently, the clay should thus be translated exactly into aluminium. Including all the fine details and surface transitions.
Like a tailor made suit
Coachbuilder Bas could opt for a paper mould to do this. Similarly to how a tailor made suit is made, for instance. The different flat parts sewn together, make the three-dimensional suit. However, getting the complex geometry and form information into a paper mould is near impossible. An alternative is making steel moulds. These can also be used as a base for beating the aluminium into place. Unfortunately this is costly. And the metal moulds will not be reused, because this is a one-of car. Applying two layers of tape on the clay crosswise is generating a similar type of mould. First Bas has meticulously applied the tapes on the body. Then he carefully removed the tape sandwich as one unit. With that capturing the shape of the Breadvan Hommage. Through these moulds the coachbuilder has enough information on the shapes. Therefore he can now precisely copy the mould in aluminium.
Design for Coachbuilding
Bas hand makes every sweeping line from flat sheets of aluminium. To achieve volumes out of a flat sheet, he can actually only do three things. He can stretch, shrink and bend the sheets. He does this manually as well as with machines. He starts with roughly giving this sheet the correct contour. The tape template made earlier is used for this. The correct order of each and every operation of shaping is of paramount importance. After meticulously planning every step of the way, the coachbuilder will stick to this. Each action on the material is followed by a reaction. To make the curvaceous body of the Breadvan Hommage is to discuss. The work is based on our design sketches. Together we continuously discuss how to make the car look best. How does the light react on the surface transitions? Which design feature can be made even stronger?