for the CRC
The 1962 Corvette is a classic style still enjoyed by young
and old. The first retro 62 took six years
and over 5000 hours to make the modifications and complete
the car. A stock 62 body was used to fit over the 93
chassis, which had to be lengthened to properly align the
1962 body. Engineering and construction on the full front
tilt took a year to complete. The car became a show favorite
throughout the Northwest and won many awards as well as second
In 1994 the first prototype was started on a C4 Corvette.
The concept was very unique and many inquiries came in on
how to purchase this car. This interest sparked a parallel
project, which started with a C5 Corvette and several months
of hand shaping the new design. Inspired by the classic 62
Corvette, Dougs new design took advantage of the larger
C5 platform. He chose to use computers in the design process
to ensure precision of the body panels and the ability to
repeat the same exact structure each time. Resolutions (now
REALADI), an organization within Boeing Phantom Works, was
hired to scan the design and convert it to a 3D CAD program
(3-dimensional computer aided design) using reverse engineering
technology. This same technology is used in the airplane designs
and the NASA Space Shuttle program.
the Boeing computers, Doug worked with technicians to ensure
his design flowed and the body shape was refined into a Class-A
surface. This created a surface and preciseness beyond the
naked eye that tested all curves, edges and radii.
With the body surface complete, the body was removed from
the chassis and the same precision process was used to map
and identify all the mounting points and clearance issues
with the sub-structure.
A test fit was done on the Boeing computers to check the
motion of doors and other moving parts, allowing the engineers
to identify and correct any errors before the molds were constructed.
This also allowed us to discover how the body would behave
when attached to the chassis.
Boeing, REALADI and the CRC
Participating in Boeings Chairmans Innovation
Initiative Program, A TEAM of select engineers elected to
spin out of the Boeing Company forming REALADI. REALADIS
brand of reverse engineering creates geometric computer aided
design models for objects when no such model exists. Combining
precise coordinate data captured from the surface of the actual
object with whatever engineering data might already exist,
engineers create a computer aided design model tailored to
the customers application.
To reproduce an image, a point cloud is needed
that precisely spells out its dimensions so that it creates
an electronic 3-D image. This is done in a number of ways,
through laser interferometry; projected white light grid patterns;
physical contact (touch-probe machines that physically measure
the item); or an integration of all three processes.
Once the coordinate data was completed on the CRC, several
software packages were used enabling the creation of the computer
aided design model. The model could then reflect the data
directly and offer engineering definitions, such as thicknesses,
hole sizes, and datum planes.
Since their departure from Boeing, Classic Reflection Coachworks
has continued to work with REALADI to improve and add parts
to aid in the assembly of the cars.
model data, that became the CRC, was transferred to a specialized
tooling company that used the information to define paths
for a five-axis milling machine.
The first step was to confirm the design aesthetics by creating
a half-scale model of the car. Once Doug was satisfied with
the overall visual appearance, he instructed
tooling company to create the first in a series of molds that
were needed to build the final high temp vacuum molds for
all the body panels.
CRC body is made from SPRINT CBS, a unique composite material
by Gurit, used by several companies in Europe for the Aston
Martin, the Mercedes SLR McLaren and the MG X Power SV. This
composite is shipped to our shop frozen from England. The
material is a balance of Carbon Fiber and E-Glass layers placed
on either side of a precast, precatalysed resin film. Unlike
conventional prepregs, SPRINT fibers remain dry and unimpregnated
by the resin until the curing process. This gives the materials
their outstanding breathability, high strength and achieves
autoclave quality laminates from vacuum bag processing. A
surfacing material is placed in the mold prior to the CBS.
After the vacuum bagging process and high temperature cure,
the parts are treated with a DuPont paint system which has
been developed for use on this material. The surfacing material,
along with the DuPont system virtually eliminates any pattern
bleed through on the outer surface ensuring a remarkable finish.
CRC conversion is more than replacing and bolting on a few
panels on a stock C5. Every panel on the C5 is replaced with
a computer engineered, vacuum formed Carbon Balance part.
Each individual part is made without seams to prevent printing
on the outer surface. The rear section of the car is permanently
attached to the C5 frame and all other parts are attached
using removable fasteners. The car was designed to use factory
stock parts (hinges, wiring, interior appointments). The bumpers
and most of the chrome trim are manufactured specifically
for Classic Reflection Coachworks.
Each car is hand crafted, panels and trim are custom fit
and the car is painted any
color the customer chooses. A new soft top is installed and
the car is cut and
buffed ensuring a quality you find only in high end show cars.