How to carve a Mini Cooper from a block of wood

[solidmodeler]

This thread will have a step-by-step photo-tutorial of how I carve a basic scale model automobile from a solid block of wood.

The project will be a 1960s Austin Mini Cooper in 1/32nd scale from basswood, known as lime in the UK. I am using a four-view drawing from the the sitewww.the-blueprints.com.

[tom120934]

You should write some posts here to make some room reserved for your tutorial. It will be easier to follow it. I'll remove my post as soon as you posted some.

And thanks for posting it here, looks damn promising !!!

[greenvampire]

now yer talkin! cant wait to see this one develop

[solidmodeler]

I started this project by reducing the drawing to the correct scale and also creating a mirror image of the car's side view with photo editing software.



Next step was cutting a block of wood that is somewhat larger than the maximum height and length of the scale Mini. The thickness of the wood can match the car's maximum width exactly. I used a band saw for this, but it could be done with some type of hand saw too, basswood is fairly soft and easy to cut. The most difficult task here is making sure the sides and top of the block are square to each other, it helps if the sides are true. A carpenter's square and handplane can take the place of a decent table saw to achieve this.



Glue a side view onto the block. Center it, leaving a little extra wood all around the pattern.



Using a square, I drew some vertical lines from the center-line of each wheel to the bottom of the block, then continued the lines on the under side and around to the opposite side. these lines will help me glue the other side view in the correct location.

[greenvampire]

its going to be really interesting to see this progress

[crazy 989]

^ ^ +1 cant wait

[hmg2007]

wow I'm going to keep an eye on this project also. can't wait to see more.

[tom120934]

It's indeed very interesting. Keep us updated !

Are you in the process of currently carving the car, or is it already completed and you're now writing the tutorial ?

[solidmodeler]

Tom, it's a true work-in-progress, so if I mess things up, you get to see that too. I'll post more later today.

[Unicorn]

This will be really fun, cant wait

[solidmodeler]

Today I cut the excess wood away with a band saw. I could also saw this by hand, and that is where it really helps to have a pattern glued to both sides of the block. Allowing me to check both sides periodically to keep from cutting into the car.


Carefully trimming down to the outline...


I take a small sanding block and smooth down the saw blade marks. Now it's a "square" body.

Draw a center-line completely around the car. This line is exactly half-way between each side. One way to do this is by taking a small strip of paper cut the same width as the car, fold it in half to get a center point, use this home-made ruler to transfer many points to the wood with a sharp pencil and using a flexible straight-edge, connect the dots. I can shoot some photos of this process if it's not clear.

[solidmodeler]

[solidmodeler]

Sawing the inside of the wheels...


I used a chisel to begin cutting away the excess material...


Stick a pin or divider point through the center of the wheels on the drawing to leave a mark deep in the wood. I use this point later to draw circles with a compass...


With a small chisel I begin paring down the wood to represent how the wheels are slightly recessed within the wheel wells.


Pare away some of the excess material on the underside...

[schaefft]

I have to say its really interessting to see the progress you are doing here.

Kinda reminds me of the days when I created cars with brushs in unrealED2.0, pretty much the same technique, just digital.

[greenvampire]

looks awsome, really enjoying watching this come together

[solidmodeler]

Well Schaefft, this my own version of "3D solid modeling". I haven't learned the unreal method, but maybe there is some hope...


Both sides trimmed, making a rough chassis...


Removing excess material on the top side...

[tom120934]

It really begins to take shape. Great job, please keep us updated, I'm really enjoying your thread.

[solidmodeler]

The idea here is to create the basic planes of the car's surface and gradually refine them into curved surfaces. There are very few (if any) straight lines on an auto body. Here I am creating some templates for the top and bottom of the windshield. I trace the lines to paper and transfer them to card-stock...


Next, transfer the top line to the wood and use the bottom template as a guide (lines cannot be drawn on the wood for this)...


Slowly pare down the curved surface...


I finished the windshield (for now) with a sanding block...

[nb]

Very interesting indeed. I've done a lot of wood working in the past myself, so I enjoy following the thread. One simple question: why do you have the wheels united with the body? Wasn't easier to carve the openings for the wheels, turn each wheel separately and then attach them to the body?

[solidmodeler]

nb, thanks.
Actually, I thought it would be less complicated to make the whole thing from a single block. The wheels on this model are small, just over a half-inch in diameter. Turning them might be difficult.
It would be interesting to make a car with spinning wheels. I'll have to try one eventually.