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yogi-bear

Scratch Build of BTCC Volvo 850 Estate

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I've always been keen to scratch build my own rc car body. So I finally decided to take the plunge and for my first attempt I've decided to do a 1/10th scale Volvo 850 BTCC Estate as raced in 1995.

I've going to use a Tamiya FF01 chassis, the one Tamiya uses for its Volvo sedan 850 version. Although I am tempted to make some additions to the chassis if I can get the body finished.

So initially I had to work out how big to make the car. Obviously 1/10th scale is a pretty good clue, but just to be sure its going to match up the FF01 sizing I printed scale stickers and overlaid the chassis.
Volvo-850-BTCC-Estate-build-02.jpg
Volvo-850-BTCC-Estate-build-01.jpg
Once I was happy with the sizing I needed, I then had to work out how I wanted to make the body. As I intended to drive this car, I thought polycarb is probably the best choice. I did toy with the idea of completely scratch building, but I am lazy :D and figured I might as well make use of my little chinese cnc machine. Still to get a decent body that still means making a pretty decent positive and vac forming (which I don't have - yet).
I initially thought I'd have to make my own 3D model, but soon came to realise that it would take me quite a long time to do. Mainly because I am time poor and won't be able to keep at it. So I started surfing the big old internet and was lucky enough to find a free 3D model of a very similar Volvo - the 960 and used that as the basis.
I then used Autodesk's 123Make program to generate 6 mm slices of the car. These slices I tidied up a little and then imported them into Cambam. From here I can make the appropriate g-code and cut them on my cnc machine out of 6 mm MDF.
Below are some of the slices in Cambam.
Volvo-850-BTCC-Estate-build-05.jpg
All up there were 68 pieces to cut.
Volvo-850-BTCC-Estate-build-04.jpg
Once cut, I then had to trim out the pieces and put them together.
Volvo-850-BTCC-Estate-build-06.jpg
Here you can see a test fit. Once in position and securing together I think this will give me good base from which to start. Although next time I am tempted to use 3 mm MDF instead. That will double the cuts, but should make finishing a lot easier.
Also once the pieces are in place, the car will sit up off the ground.
Volvo-850-BTCC-Estate-build-07.jpg
The next step after cleaning up and joining them all together is to cover the whole lot in shellac. This will make the mdf much stronger and also lock down the fibres so I can create a smooth surface. Then I can start bogging (or model clay undecided which to use) and sanding to get the final body shape.
I'm really happy with the progress so far (all up about 4 weeks here and there), but I know there will be issues with the front and rear bumper. I'd like this to be as accurately as possible, but vac forming won't allow over hangs as you won't be able to remove the mold.
So I have them two options, firstly simplify the bumper area, or do what Tamiya have in some cases, and that is make an extra piece that will fit on and give the detail you can't get from polycarbonate.
Now I will apologise in advance, as I will be probably slow to update this, but I have a goal to have this body finished and painted by the end of the year.
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Fascinating - remembering that crazy-looking touring car, too, I hope you succeed in making the shell!

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Wow, I am definately subscribing to this thread. Good luck with the project.

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Holy crap!! That's looking fantastic! Gonna be following along for sure!

Not sure if you've seen the bodies made by retro-racing out of Finland (like the Mk1 and Mk2 escorts) those were made in 2 pieces which took care of the overhang issue. Down side is the body was joined at the rear of the front fenders.

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Cheers everyone.

Trini2DBone: nice bodies :D , it would be nice to get one of the Mk 1 escorts too.

I'll have to think about this, but I think joins around the fenders isn't too bad. I have a Pantera body thats like that and it was alright as long as I joined it properly. I could probably do something that encompasses the rear tail gate and lights so its not too noticeable. I'd also like to machine the front grille in aluminium, so that might affect things a little.

My next step join it all up, do some minor smoothing and then shellac it a couple of times, so hoping to post that by next Sunday,

cheers

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One of my favorites. I daily drive a 1:1 850 T5 wagon. Definitely interested in the final product.

57f2e4ec9ba961edf49765d8d91d6fcb.jpg

My actual car/tamiya transporter

f67fe78555f0652ce78c8efce985150e.jpg

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One of my favorites. I daily drive a 1:1 850 T5 wagon. Definitely interested in the final product.

. . .

My actual car/tamiya transporter

Nice T5, my inspiration for the build was also my 1997 V70. Great cars, I've always had respect for Volvos growing up, as Dad had a few and he was very hard on the (he's very hard on all his cars!) and they seemed to survive the best.

Volvo-850-BTCC-Estate-build-12.jpg

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Don't forget the 1/10 stuffed Labrador for the boot...

haha, Volvo drivers in Australia are noted for also have Terry Towling hats! and driving slowly in the fast lane (that does sound like my Dad though!)

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ok, minor update. I stapled the pieces together, and yet again discovered that hindsight is a wonderful thing. When I made the slices, the software also generated alignment holes. In my haste I decided not to drill them, which was silly as I just program the cnc to do it. So the final shape is ok, but it would have been a little better with the two alignment rods I think. You can tell around the rear wheel arch is sags a little.

Volvo-850-BTCC-Estate-build-09.jpg

Volvo-850-BTCC-Estate-build-08.jpg

Then I covered the whole car in shellac, which is just a cheap lacquer that my mum had :rolleyes: . This will give the MDF some extra strength, hopefully help get a smoother finish and protect it if it gets wet when putting the clay on.

Volvo-850-BTCC-Estate-build-10.jpg

Volvo-850-BTCC-Estate-build-11.jpg

I let that dry one day and started to apply some air dry clay so I can smooth out the surface a little before sanding. I was initially going to use car body filler, but then I thought the clay might be easier to sand and it was cheaper. What I didn't count on was the clay doesn't seem to want to stick the newly lacquered surface very well. So as a test I just did the windscreen and bonnet.

I'll let that dry and then will try and sand it down, along with the roof racks off at the back of the car that I don't need.

Volvo-850-BTCC-Estate-build-13.jpg

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Don't forget the 1/10 stuffed Labrador for the boot...

haha, Volvo drivers in Australia are noted for also have Terry Towling hats! and driving slowly in the fast lane (that does sound like my Dad though!)

At one of the BTCC rounds in '94, they apparently put a stuffed Labrador in the boot of the 850 Estate for the pre-race parade laps. There's a rumour that they left it in for the race too, though I can't find any photos of it.

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At one of the BTCC rounds in '94, they apparently put a stuffed Labrador in the boot of the 850 Estate for the pre-race parade laps. There's a rumour that they left it in for the race too, though I can't find any photos of it.

haha, I just googled that and it seems to be true, I found this quote from one Volvo forum:

"The Volvo 850 estate was by far the largest car in the series," explains Rickard Rydell. "Our competitors, who were taking part largely to strengthen their sporting image, were not pleased about having to compete with an estate. There were a few taunts from other drivers – but that was no problem. To wind them up, in one heat we drove with a large stuffed collie in the boot during the parade lap!"

I think if I ever it this finished the dog has to be done :D

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Ah, that's why I couldn't find a pic then - wrong breed. :D Here's Rydell and the dog on the roof - note that hand holding him on !

other09112901-a.jpg

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Ah, that's why I couldn't find a pic then - wrong breed. :D Here's Rydell and the dog on the roof - note that hand holding him on !

other09112901-a.jpg

That is a stuffed animal I believe but cool pic all the same

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That is a stuffed animal I believe but cool pic all the same

I don't think anyone ever suggested it was a live dog. Though that would have been worth seeing through the in-car footage during the race...

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ok, a rather embarrassing update :wub:

so I ended up using car filler to smooth out the bumps. The mixture was 50:1, and you only get a tiny tube of harder, so I just guessed it. Turns out I didn't use enough hardener and it tools weeks to harden, and even then its still not quite hard! Plus I put it on too thick in places.

Volvo-850-BTCC-Estate-build-14.jpg

Volvo-850-BTCC-Estate-build-15.jpg

But thats not the embarrassing bit. While waiting for the filler to harden, I cut some paper templates so I can get the curves on the windscreen and bonnet right.

I overlaid them to match up the position, and they didn't fit, being way too big. So I placed the body next to my FF01 chassis and darn it, I made the body too small!

Volvo-850-BTCC-Estate-build-16.jpg

Too small to use, I will have to start over. Which I am actually happy about in some ways. Not only is the filler an issue, I'd nail gunned the body together and it wasn't the best, as well as the body not being perfectly lined up. So I've resized and re-cut all the slices. I was intending to go down to 3 mm slices as well, but the Autodesk program I am using to make the slices wouldn't let me. I also included two alignment holes and I will use 6 mm aluminium rod (because thats what I have!) to help align and hold the slices together. I'll still keep the first attempt to test on too.

Volvo-850-BTCC-Estate-build-17.jpg

14 sheets this time and only just finished them today. I would have been done earlier except work got in the way and I needed to also tidy my workshop. To help me I made a tool cart from scraps I had.

Volvo-850-BTCC-Estate-build-19.jpg

To help me model the Volvo, I waited patiently on ebay for a 1/24th Scale Tamiya model kit. They go for a pretty penny too, I was surprised at how popular they are. It took me 4 months for me to get one at a price I could afford!

Still I felt the price was worthwhile, as it will not only give me decals which I can copy, it will give a template for a roll cage, dash and chassis. The second part to the project will be ditching everything bar the front suspension and motor mount and trying to make a scale chassis and rear suspension (or as close as I can get). I intend to use 0.6 mm aluminium to make the panels and brace it with 2mm or 3 mm segments. I've done this once before for a sand scorcher.

Volvo-850-BTCC-Estate-build-18.jpg

Sand-Scorcher-Build08.jpg

more pics of the sand scorcher here:

http://www.tamiyaclub.com/showroom_model.asp?cid=122224&sid=35302

but I will need to upgrade my cnc machine before I can really get into this part of the build. I can cut Aluminium on my cheap chinese cnc machine, but its only 200W and it struggles a lot!

Thats all for now, hopefully will have more pics of the Volvo together in about 1 weeks time,

cheers

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Thanks Dorvack, Pepakura looks pretty cool, I had not seen that before. I am currently using a 3D model of the 1994 960 model to make my slices. And while similar I will have to make modifications.

There are 850 versions out there on the web, but you have to pay for them (around $75 USD last time I looked). There was apparently a Vovlo game as well that had a wire model, but I have had no luck finding a copy.

But that looks like a great way to make a quick and cheapish body. Have you used it yourself to make any rc car bodies?

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hi Yogi , this looks great, if needed, i can help you out on a 1/24 Volvo, it's built but you can pull it appart if needed

cheers Bullfrog

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hi Yogi , this looks great, if needed, i can help you out on a 1/24 Volvo, it's built but you can pull it appart if needed

cheers Bullfrog

Hi Bullfrog, thanks for the offer, I'd wish I'd know that about 1 month ago! I've bought the 1/24 BTCC estate, and because I can't help myself I also managed to get hold of the standard station wagon version. Knowing me, this also means to complete the set I'll eventually buy the 1/24th scale sedan version too :D

Although, just out of interest, how much did you want for the model?

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Hi mate, just enough to cover postage mate , cheers Bullfrog

cheers! I'll take you up on that. I'll pm you.

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ok, now back to square one :rolleyes:

have cut all new pieces, 78 in total (except have to re-do two at the front), with alignment holes. I'm thinking I'll glue each piece together this time, and then they'll be mounted onto 6 mm aluminium rod. I've also found a better modelling clay that is softer to work with, yet still dry hard.

Volvo-850-BTCC-Estate-build-20.jpg

Volvo-850-BTCC-Estate-build-21.jpg

Volvo-850-BTCC-Estate-build-22.jpg

Volvo-850-BTCC-Estate-build-23.jpg

Volvo-850-BTCC-Estate-build-24.jpg

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Wow...looks pretty sweet...nice job...! Looks like it will be easier this time around to level out and fill ! Can't wait to see more...!

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Cheers Trini2DBone, the roof and sides I think will be pretty straight forward. Sculpting the front and rear bumper bars should be a good challenge!

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