Next step is to cut the wheel arches. I scored the arches in the bottle several times until they broke through. It's very easy to slip here, wreck the whole thing, lose an expensive bottle and have to start again. The base was cut with the usual bandsaw method.
This is probably the easiest part of the project. Cut it out with bandsaw, file off any high spots and sand it down.
I used a piece of thin chipboard for the base but plywood or foamboard would work just as well. Be careful not to squeeze the bottle sides together as you mark out and then cut about 1mm inside the line to allow for the thickness of the bottle.
The next step is to mark out the wheel arches. Choose a suitably sized washer and line up the hole with the edge, then draw round it with the permanent marker.
Cutting out the bottle required a great deal of care. I used an extendable knife and gently scored it several times until it broke through. For the tougher parts I used a pair of side cutters. Ideally the thing should be filled with something that solidifies so it can be cut on a bandsaw, but I couldn't think of anything except ice! A belt sander finshed the edge off nice and cleanly.
By clamping the bottle securely and choosing the exact level for the cut it is easy to mark out the cutting line with a permanent bullet-point marker.
It is important to fix the bottle in a rigid horizontal position before marking out where it is to be cut. To do this I cut away part of the base and inserted a clamp, fixing it to my workmate.
No one seems to have done this yet so I thought I would have a go. I have a parking area for the pits and plan to have a couple of car transporters and trailers there. Inspired by an advert in Autosport I thought I would try converting this plastic bottle...
into a covered four-wheeled trailer like this...
Well, this blog is only a month old and had over 800 viewings so far. That is very satisfying and encourages me to keep posting. Many thanks to all those of you who have viewed and especially to those who have commented. I will try to keep it interesting and informative, so keep coming back!
I know it's not really a barrier but getting under a ten second lap time became a bit of a mission for me. My newly chipped Seat Leon did it with 9.87 secs. Surprisingly it's a bit quicker than my Maserati but being much shorter it doesn't waggle about so much.
By the way this is a photo taken before I started building my track, taken on the dining table!
Step eight: cutting out the wheel arches
Step seven: cutting out the base
Step five: mark out the base
Step four: mark out the wheel arches
Step three: cutting the bottle
Step two: Marking out the cutting line
Step one: cut bottle and clamp down
Creating a trailer
Month old and going strong
Ten second barrier broken