WIKISPEED Shop in a Box molding shop 

Basic Structure

  • 40’ x 9’ x 8’ single use steel shipping container
  • Hardwood deck
  • Full opening center catch doors

Interior Additions

  • Full width full height storage unit fixed to the rear wall of unit for the containment of the fiber cloth rolls and the bonding materials
  • Beginning 6’ inside the structure 1 foam board affixed to the sides and ceiling for 20’
  • Roll-up curtains at each end of this insulated section / or pole stand curtains for each end of the insulated section
  • Ceiling mounted RV type heating unit that uses either propane or diesel fuel
  • Ceiling mounted electric generator, where lack of infrastructure dictates, for lighting
  • LED light bars with angle reflectors on both top sides of the interior with extensions for the exterior work space
  • Floor and wall tie downs for securing items as needed
  • Electrical outlets as required for power tools and/or chargers
  • Brackets on inside surface of the doors to mount 4’ x 8’ extension panels and structural support bars
  • 2” x 2” x28’ aluminum angle x 2

Additional Material Items

  • Truck tarp to enclose exterior work space of 12’ x 20’
  • 10 – 4’ x 8’ OSB ¾ sheets with hinge attachments and eyelets for scaffold braces to construct
  • side wall extensions
  • 4- X type scaffold braces to support exterior side walls
  • 10 – 12’ x 1” diameter conduit sections to support the tarp and define the width of the container extension
  • Mandrel cart with 6 dia. full rotation wheels to carry the body mold
  • Body mold
  • Vacuum table fixed in the rear portion of the container for the molding of light enclosures, mirrors, windshield and roof panels
  • Cable pull block and tackle for moving the cart and lay-up mold in and out of the container
  • “T” handle extension to control the cart when moving it in or out of the container
  • Portable lights and stand for the extension room area
  • Work bench for hand work

Delivery System

  • Secure the tools and layup materials in the rear storage cabinet
  • Place the 10 sheets of OSB banded centered and tied down to the floor in front of the cabinet
  • Place the 10 sheets of foam board directly in front of the OSB, banded and anchored to the floor
  • Place the mold on top of the sheet material and secure
  • Anchor the mandrel cart to the side wall
  • Lay the bundled conduit and X braces next to the sheet material on the floor and block in place
  • Secure the work bench and the vacuum tables to the floor and side wall of the container
  • Pre-mount generator, furnace, electrical outlets, track guides to floor, and LED lighting system
  • Upon delivery the materials will be checked for condition
  • Remove the external items and set up the extension room area and brace in place
  • Cover with truck tarp
  • Extend the LED lighting into the work space
  • Affix the blue foam to the interior side walls of the container with construction glue and self tapping stainless fasteners, top, center and bottom of each panel. Three fasteners 1” in from each edge and in the center divide of each panel. A total of 9 fasteners per panel will require 90 fasteners minimum for the area to be covered @20’ per side wall
  • Joints between panels should be taped with high tack thin packing tape

Manufacturing Process

  • Mount the mold to the mandrel cart
  • Affix the cable pull system to the cart and the “T” handle
  • Check the motion of the cart into the container (should move freely and miss sides of container)
  • Check heating, electric and lighting
  • Place cart in the work space and apply the release agent to the mold surface
  • Begin cutting and laying up the layers of fiber material
  • Actual step by step process will be documented by Joe Justice and Rob Mohrbacher
  • Apply the rosin catalyst
  • Smooth as needed
  • Begin heating the cure area with the curtains in place to 70 degrees F
  • Close the mold
  • Open the door end curtains of the cure area
  • Move the cart and body into the cure area
  • Secure the curtain and cure for ??? hours
  • After cure cycle move cart to work area
  • Remove the external mold features
  • Begin the hand finishing of the body (Joe and Rob to provide details)
  • Set up the vacuum table and form the light pockets and lenses plus the mirror housings
  • Set up table to form the wind screen
  • Prior to removing the body from the mold mandrel clean the entire work area
  • Inventory material use to determine what is needed for the next body
  • Place order for additional materials
  • Remove body from mold and secure on chassis

Rinse and repeat

The sketch detail will be sent in a photo format showing the placement of angle, room extension construction and cover, the placement of the insulation panels

This is a proposed concept not to be considered a volume production facility.