03/19/2026
Starting to move past design on a number of items, particularly those applied to the chassis. In preparation for the cage, I made these gussets both for my own car and a friend’s S6 project in Japan. These were fun. My first design wasn’t great, due to the fact that I just estimated where the end of the part would be since the scanned part was already welded and there were pretty fat weld beads in the scan. The fix was to model the cage, scan a chassis without a gusset, align that scan to the WRC one, and switch back and forth between scans, modeling to a virgin chassis while being faithful to the bends and shapes of the gussets from the WRC car scan. Dimple dies are printed from petg cf. I also made bending dies for each bend profile….but ended up abandoning them since the metal created much sharper bends. I guess I could sell these to anyone who is interested