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Building A Carbon Fiber Body For My Flooded McLaren P1 From Scratch Is Harder Than You Can ImagineAdded:
All right, second channel time. And I know I say this in every single video, but this is a different kind of video because I am doing the first, second, and third, probably all the way up to 10th steps to make my P1 Evo body. And behind me is not my P1. I'm actually here in Denver. I'm at the HQ of the Car Council and I have been hard at work for the last probably month and a half getting this P1 together. Now, you guys have probably already seen this on my main channel, but we're sort of recording this out of order because uh this P1 is the only P1 in existence to have been built not at the McLaren factory. This is a P1 that we built entirely out of spare parts. It's been quite an ordeal, but I wanted to talk to you about my P1, my P1 Evo, the fastest McLaren on Earth that hopefully will be the fastest McLaren on Earth. I am developing a brand new body. And I know a lot of you saw the episode with Frank Stephenson, the original designer of the P1, and he designed a body. Today, we're going to take the first steps to actually put that body on the car. And the first step to that is we have to 3D scan this without a body, which means that we have to do I mean quite a bit of scanning because there's a lot of surfaces here. There's a lot of things that things mount to. And um I don't know anything about 3D scanning, but one of my friends does. And uh that is Nelson right here. He's just uh he's just sitting chilling.
Nelson has been on Netflix. He's been uh all over the internet. And uh he's done quite a bit of carbon work. carbon fiber work uh up to like the OEM OEM plus level uh that that sort of thing. So um we are working together to hopefully make the first body for my P1 Evo.
>> Yep, that's right. So yeah, I've done quite a few composite based things, you know, over the course of the decade in which I've been, you know, a creator for the composite industry. So full carbon fiber Viper, uh ACR, nonACR, full carbon fiber, uh Dodson, we call it the Ronin, that's for my friends at Gayscale. And uh yeah, even full carbon Corvettes for like Lingfelt or Cunningham. As far as the amount of people that have built full carbon, full platform development vehicles in the country, I would think I'm uh one of the only few and I like to be behind the scenes and Tibar is putting me in front of the scene now. So we're doing that now.
>> Yeah, you're in the scene. You You are the scene. Look at Look at this man and his hair and his hat. Oh, look. It just It's just wonderful.
>> We're the same age.
>> Yeah, we are the same. We're the same age. and and look at this is what the stress of a P1 build does to you, ladies and gentlemen. Don't do that. Be be like him. Look, he's he looks great. So, we have put little tiny dots all over the car. These are self-adhesive like little stickers. What we're going to do now is we have a a really expensive scanner um that is going to scan this entire car and we're going to get all the the pickup points for where the body would bolt on. So, uh, where the clam shell would bolt on like right here and right here and like all this stuff, we need to know because that is what's called, is that called a B surface?
>> The A surface is going to be the exterior or the art file. That would be the design of the P1 and how it CFDs.
The B surface is going to be how all that mounts securely and safely. So, when he goes to be how fast you trying to go >> really fast like like super super like over 250 60 70.
>> Yeah. So, what is going to hold the car together at those 200 plus mph speeds, which um I've built uh two cars that have gone over 230 in my time with our carbon. So, we are qualified.
>> So, when he says we're qualified, um I'm not qualified. I don't I don't know what I'm doing. He has a very expensive scanner. I don't want to touch that because it's really expensive. But, uh it is an all-in-one scanner. It's basically just a computer and scanner and everything in one.
>> So, we're going to be using blue laser.
Uh about 150 lines of that. We're going to be using 39 lines of IR as well as LAR. So, we're using all three of the main feature sets aside from meteorological and uh uh surface based to get us the most accurate scan of a P1 chassis humanly possible.
>> Can that drive itself?
>> It's going to be a massive amount of data. We're going to be talking I mean hundreds of billions of polygons and triangles to get the full gamut of what this is. But the better data point that we start with, the better we can B surface and the better the our friends at FSD, Frank Stevenson design can do the A surface, which is going to be the outer shell.
>> We need that because the design that we have now, it's uh basically just a rendering. So the rendering is very loosely based on uh a model that we found online. So it's not necessarily based on an accurate scan of the car.
And for us to make a production level body kit, I think we're going to need something that is as accurate as possible because what happens is like, oh yeah, we can 3D print a mold and blah blah blah and we put it on like this doesn't have any Yeah, it doesn't fit at all. Uh so that would be bad. Also, if we ever wanted to make more of them, >> uh we could. So this is exactly the way uh you would do it in a production facility. Um, and the good thing is if we're going to have this data, this should be other than the factory, the most accurate data out there for a P1 in terms of 3D scanning.
>> Yes, it would definitely be in the running to be the most accurate. I can't speak for other facilities that may have some capacity, but I don't >> I will Okay, we're going to have the most accurate data. And if you want to buy that data, >> then you can't because we're not going to give it to you. All right. So, just in case I didn't make myself abundantly clear in this episode or any of the other episodes talking about this car, I want to make my P1 the fastest McLaren in the world, which means I have to add performance on top of what was already there. Now, back in the day when the P1 was brand new, it was very, very fast.
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>> Take a look at that. We are surfing through cyerspace over here.
>> So as you can see, you can see the laser grid start to capture data. that's anchoring to all of our reflective dots cuz that's how that needs to happen. So, this is using a combination of laser gridding, which is the lines that kind of intersect. That gives us the definition of height.
>> This is still a uh not perfect process because um you have these carbon fiber elements and those are notoriously hard to scan because they have well they're they're slightly glossy. um they're they're reflective and black and I know that that makes things a little bit difficult but uh with the laser at least in theory it should be a little little bit easier because we have those reflective dots on there.
>> Yeah. So the LAR system is going to be pinging the dots with the IR and giving us what we call anchor points which is where the lasers will then kind of overlap in a waffle cone pattern to give us dimensional accuracy as reference.
The trick is you kind of have to do it in an overlapping pattern and be a little bit slow because you really want to capture the most data.
>> Today's kind of an unusual day, isn't it?
>> Yeah, it is a weird day.
>> Do these weird days happen to you a lot?
>> Yeah, all the time.
>> That is so cool, man.
>> So, you can see all of the >> the car just basically as a wireframe and then it's adding to it uh the more you scan. So what happens if you like miss a certain part? Will it just be like a hole?
>> Um yeah. So it'll make the the initial rough data body and you can go back and fill the holes or you can post-process them and it'll make some assumptions too because it does have some logic to kind of go back and go like oh I missed this spot. The scan data will get you about 85 maybe 90% regardless of the scanner.
There's always a post finishing aspect that comes after the fact >> and that's where me and Mr. and Frank are going to have to put our heads together to kind of add some some missing missing bodies.
>> Or we can, you know, >> take several scans and and interplate them together to create one full scan.
Does that make sense? So, you can actually use markers like textures and shapes to realign the data. It's actually like you load all the files, you press a button, and it's like boop, here it is.
>> So, it's really quite simple.
>> Yeah.
>> So, if necessary, we can do that. My hope is not to. I just need to get the primary body scan data.
>> And what kind of scanner is this? So, this is an Ein uh Libre.
>> Mhm. Ein scan Libre.
>> Yeah, Eincan Libre. I get it confused with Einstar cuz I have an Einstar as well. It's a lowerend scanner. So, this is a Libre and this is the like pro version of that.
>> Now, we do see that um you know there is a strap here. I'm not worried about this because um we're not going to be changing anything with the uh the door closing dimensions at all. So, uh, this will essentially just be a hole in the scan, but that's okay because we're not going to be using that anyway. The car is going to have doors. We're just trying to get this, which the clam shell bolts onto. Uh, we want to get all of the mounting points here and in the front. It is so crazy that this is possible right now.
>> Yeah.
>> Like it's it's still expensive, but like it's possible to do these really high quality data scans essentially in your own house.
>> It is. It is. is and you know the next leg of this uh depending is going to be post-processing all the data right so you now have a series of plots points and shapes in an abstract space how do you extrapolate that to become a reality and that's one of those things that um is actually very expensive takes a tremendous amount of um >> like computer hardware as well as a tre tremendous amount of talent and time >> yes >> it really does so you know this is technically the easiest Uh what comes after this is going to be interesting.
>> Yeah, we're going to have to do something called CFD testing, which is computational fluid dynamics, which is actually aerodynamically testing the shape to make sure that this isn't going to, you know, do a back flip at 250 mph.
And then we do some more design work. Uh kind of go back and forth a little bit.
And then once we find out what the actual shape is going to be and we finalize that then and only then we can go to the 3D printing process which is for molds.
>> Yep.
>> And then uh then from molding we have to make the carbon structure and then that's also going to include like uh areas where there has to be more carbon because uh it's going to be an area of high pressure. Um >> yes. So once uh Frank and I go through the the AB surfacing and we make sure everything fits digitally, we will then go to validation which is we're going to print a series of jigs uh I have a fleet of printers from bamboos to mark forge to make it 3DS which is like a 4ft printer. It's very large >> and that gives us the ability to take our digital abstract turn it into a physical reality and then tolerance. So from there we'll fit it to the car, make body adjustments on the car because digital renders of things, you know, albeit this or 3D printing have about a 1 millm tolerance variable. That's pretty common in the industry for material shrink from printing or the inaccuracy of a scanner even as expensive as they are. So we have to then hand massage the panels into the correct shape which we then rebrace and we manufacture a mold off of that panel off of the car. That gives us a one to one body like and it gives us exact hand fitment of of every component and then the structuring. So we got to figure out the bracing system whether that's a core system whether it be from aerospace lannerosauric composits you know driven titanium fasteners you know we have to avoid aluminum because galvan galvanic corrosion is a real thing. There's so much engineering and tech and just like minute detail of process that will dictate his safety and that's something that's like pinnacle on all cars.
>> Yeah. But, um, I mean, everybody would, uh, would disagree with you because why haven't I finished this by now? And it seems like it's, uh, it's it's just a really easy thing to do just to just to make your own, uh, custom everything on a hyperar.
>> Yeah, there's a lot of people that, you know, I get the same thing like, what takes so long? And >> I'm arguably one of the fastest guys in my industry. You know, I built a car from nothing to something in 5 months.
And it's not only good, but it functions. It doesn't rattle. And it is like it crushed the internet. It was a huge deal in person and online. And you know, people really overestimate. They go, "Oh, I saw a guy on the internet print this thing and he just wet laid it and peeled it off and then put it on the car. It looks great."
That's that's true. But drive it. Yes.
>> Drive it going hundreds of miles an hour. Put it in the sun for a month.
like the quality to me will never be the initial product. Quality to me is the initial product 5 years later. And that's something that OEMs have to think about. That's what we all think about.
Cold weather, rain, acidic weather, which does happen in various parts of the country. Um fallout, like there's so many variables and you can't just say something looks nice today. How does it look in 5 years?
>> Exactly.
>> And that's the difference between highcaliber composits and the guys you see on YouTube.
>> Mhm. And I don't have a YouTube for that reason. Sorry to >> So this is the amount of pictures it took independently.
>> Okay.
>> Those are the amount of markers 700 and the amount of points of in the cloud that it generated.
>> Wow. Okay.
>> So 7,787,515.
>> So 7 million points of data and uh we have this on top of a toaster oven apparently. This is super super cool. So it is basically putting this all together into one um kind of usable thing.
>> Yeah. It's going to give us a final um mesh file.
>> Mhm.
>> So this is the the record of data plots and points in an abstract space and now it's going to put it all together and go here's a body.
>> Awesome.
>> Yeah.
>> Okay. And then uh when it crashes and uh we have to do the whole thing over again like >> that's uh we like >> that's why I plug in.
>> Yeah. plugged it in cuz I was worried about uh it timing like my battery is dead so I got to let this thing >> charge but I don't want to lose any of the data. It should recover it but this is a massive file. I think this file is almost 90 gigs.
>> Wow.
>> Yeah.
>> Okay, cool.
>> So 90 GB of data which is enormous. Um >> and we still have to do like the the underside but that can be done kind of kind of quickly.
>> That should be quickly. Yes. I mean this should have been much quicker than this.
Um, but it's taking longer because you have glossy parts, metal parts, matte parts, carbon parts, carbon gloss parts, painted parts, and some gold parts randomly.
>> Mhm.
>> That's you.
>> Yeah, that's me.
>> I like gold. Sorry.
>> Yeah. Thank you for making this like a cluster of hard to scan.
>> It's okay. It's all It's all right, man.
You know, you got the you got the thing.
All right. You know, it's >> back in the day if you didn't have this.
I mean, you you just have to be like, you know, all right, that seems all right. It's good. Back in the day it'd be we would do this with uh what's called chioant clay.
>> Sioant clay.
>> Yeah. You ever seen that? It's it's like the red orange clay that they used to sculpt with.
>> Oh yeah.
>> Yeah. It's called Siobhan clay. Yeah.
>> Oh wow. Okay.
>> Which we also can do. We've done that many times.
>> So I know that the uh car manufacturers they still have clay models. Is that what you're talking about?
>> Yeah. Yeah. That's that's the physical way of making a body cuz you can technically pull molds off chant clay.
That's why it's designed to be inert to polyester, vinylers, and epoxies. So it's a it's actually a pretty specific clay. It's also very expensive. Okay.
>> Is there a cheap way to make a car?
>> I mean, are you like I could build a car in my backyard and it would be a car.
Would it be a hyper car?
>> Good.
>> Would be nice.
>> Good.
>> No. That's for all those YouTubers out there saying they could build a car.
>> How Why are you pointing He's He just pointed at me. Why are you pointing at me? He's like YouTubers. Like look, hey, man. Like I just I'm just trying to do the thing.
>> The YouTube comments. That's be >> Yes. Yes. commenters that have been that have been obviously doing this for 5,000 years. They know what they're doing.
>> Yeah. The people building their Fiero in their backyard that's still not done yet.
>> They're going to tell you that what everything you're doing is wrong.
>> Yeah. Their cousins, brothers, girlfriends, whatever.
>> My I'll tell them the same thing I tell everybody. How many carbon fiber cars have you built?
>> Well, it's cuz the streets ain't ready.
So, that is a P1 sort of skeleton. Look at that. That's so cool.
>> Yeah, >> dude. That is That is nuts.
That is so cool.
>> So after an hour of crunching, uh it has finished the final mesh.
>> Okay. So we should we should have some pretty good data with that.
>> Yes.
>> Okay.
Don't don't don't drop this.
>> What?
>> Don't don't drop Don't drop.
>> Oh, no. I'm not.
>> No, we're good. Oh jeez.
>> Don't don't don't.
>> Okay. Back at the shop. The P1 is right behind me. And I want to address something that a lot of people have been asking, and that is why all this is taking such a long time. Now, it's not because I haven't been working on it or haven't been uh solving problems behind the scenes or off camera. We have a lot of work to do because when you design, when you redesign a car, especially a hypercar like this with not a lot of documentation, not a lot of parts availability, and certainly not a lot of cars that you can go and scan like we did earlier in the video, then it becomes really, really difficult because not only do we want to have this car be the best version of a P1 that we can make, but also it has to be the fastest McLaren in the world. It has to be the best version in terms of aesthetics and also safety. One thing I really want to harp on is the fact that we're going to make this thing look like it came out of the factory. And because of that, we have to do a ton a ton of testing in terms of CFD or computational fluid dynamics. And that means we have to test the car aerodynamically to make sure that if it goes over 200 mph, it's not going to take off like a plane. What I've done is I've reached out to a company called Airshaper. And airshaper is an amazing software that essentially tells me what the aerodynamic profile of my car is. Now, even though we have a 3D render, and you guys have seen it in the main channel video, it's sort of like a video game skin, it's not anything that we can use for aerodynamic testing because when you do testing of a real car, you have to have everything super super high resolution. And for us to get that, we have to have an accurate scan of the car. not only underneath the body, but also the body itself. And I was not aware of how hard all this stuff was. I thought that you could just have a 3D scan of something and then basically you just plug that into another software and that essentially makes something that's 3D printable and you can slap it on the car. It's not that easy. But I know that you guys really want to see more of the car and I want to share all this stuff with you.
So, let me know in the comments if having smaller deep dive videos on this second channel leading up to a big main channel video, let me know if that's something you guys want to do because I would love to do that. I just don't know if that's going to be satisfying for uh people that want a more cathartic ending. Like, they want to see the car running and driving. Believe me, I do as well, but it does take time. So, thank you for being patient. Thank you for uh all the help with everything. I've had several people reach out and help me with several problems. But I think right now we're going to let the aerodynamic and body sections like we're going to let that breathe. And while that's happening, I'm going to focus on the mechanicals to get this car actually running and driving. And one of the things I'm going to start with is weight savings. Now, the P1 is already a relatively lightweight car, but because it had a hybrid drive assembly, it had very heavy batteries, it had a heavy e- motor, it had wiring, all that sort of thing, that contributed to a lot of weight that we can save because we're changing everything about this car. But one thing that's sort of overlooked is the hardware itself. Now, this is the OEM McLaren hardware. These are M6 by, I believe, 16 mm. They are already very lightweight. You can see that usually an M6 bolt would have a 10 mm head on it, but here they have a 8 mm head and that saves like a tiny tiny tiny bit of weight. Now, what I'm going to do is I'm going to weigh these. These are 40 bolts. Uh, so 40 volts from P1 will weigh about 9 oz. 8 to 9 oz. And if we convert that into kgs, that's24 kg. Now, while that is kind of sort of lightweight, I have something better.
So, these are JD Customs titanium anodized gold special bolts that we made specifically for this P1. And they even have Wrench Everyday engraved in the top. And this is 40 bolts. And we can just see the difference. So, that was.24 kg.
40 titanium bolts is 0.1 and to pounds 04 pounds. So this is less than half the weight of those OEM bolts. And throughout the entire car, the amount of M6 and M5 bolts would add up to a weight savings of about 15 to 20 lb. Now, you might not think that that is a lot, but considering that we're not actually decreasing any functionality, every bolt will be in its place and we're making the car look a little bit better, I think that is a huge win. Now, you guys can buy these specific bolts that I'm using on the P1 with the Wrench Everyday logo by hitting the link in the description below. Uh, this is sort of a collaboration between me and uh, JD Customs, and I can't wait to work with them more because they make a ton of really cool titanium parts, and I can't wait to get these on the car.
Another thing I wanted to show you guys is this.
This is the entire suspension, at least the control arms and the uprightes for the McLaren P1. and my friends at the luxury choices, Jonathan. I can't say enough nice things about Jonathan. He is the man. These are the original suspension components. And these are specifically made for the P1. They are very derivative of what other McLarens have, but they are a lot lighter. They have like these machined machined out sections here just to make them that much lighter. A lot of this is identical to the 675LT. The 685LT actually used some P1 components. So, that's kind of cool. We have powder coated this in this really nice bronze metallic finish. And what I wanted for this car was a finish when you look underneath the body to look like a Pagani Zonda R or a Huayra R or something where it is just as much of a work of art as it is on the outside.
So, we're going to make sure everything gets the treatment that it deserves.
Now, the bushings for the suspension would sit right here, and they're pressed in, and they have like a little rubber element, and what that does is when the suspension goes up and down, they would take some of that uh vibration, and it would dampen the uh suspension. But for my application, I think we need something that has a little bit more longevity and has a little bit more stiffness. So, we reached out to a company called Power Flex USA, and they're sending me out their polyurethane bushings, and I can't wait to try them out. Not only because, you know, they're a lot stiffer, and, you know, they're nicer to look at, but also because they should last a lot longer than the OEM rubber bushings. And speaking of suspension, check these babies out. So, these are straight out of Poland from a company called Nagen Gas that I sent out my original P1 shocks and struts, and they rebuilt them. And what I'm really excited about is the fact that these are now going to work just like they did from the factory. Just got to be very careful not to pierce anything. Now, what they did is they went over everything internally.
They took them completely apart and rebuilt them. Check that out. This is so cool. This is amazing.
All right. All right. I got to put these in a very special place because I don't want anything to happen to them. The bushings look good. Everything up top looks great. These are original P1 shocks rebuilt, ready to go in the car again. But one thing I am modifying is the hydraulic lines themselves. So, welcome to the front end of the P1. This is the firewall or the bulkhead if you're not 100 years old like I am. Now, this is where all the hydraulic lines would start and then they go underneath the car to go into the engine and suspension components. Now, how it all works is that there is a giant hydraulic pump right here and that pumps out pressure to the power steering pump, but also the suspension. And on the P1, there are very special suspension components because the suspension is completely hydraulically operated. That means ride height is hydraulically operated. The amount of dampening is hydraulically operated and also the sway bar functions because this doesn't have a traditional sway bar or anything like that. That is hydraulically operated as well. It's very, very sophisticated. But what I think I can do is I can simplify all of that. Now, I'm not taking away any functionality from the hydraulic system, but I am streamlining the lines.
If you saw my last main channel video where we put together a bone stock OEM P1, the hydraulic system looked very, very complicated and the lines were just basically going wherever. I thought honestly it wasn't designed very well.
uh because if you wanted to pinpoint an issue or if you wanted to take out one hydraulic line at a time, it would be almost impossible without taking the entire car apart. So, what I'm going to do is I'm going to start from scratch and see which hydraulic line does what.
Then, I'm going to have my own hydraulic lines made, and then we're going to have a bulkhead connector and then quick disconnects on everything. Now, from the factory, the lines that go through the middle of the car are hydraulic, coolant, and vacuum lines. And we're going to eliminate the vacuum lines because we're not going to be using any vacuum systems up here. The vacuum systems usually would be the brake booster and we're going to be replacing that with an electronic brake booster.
The kind of stuff that you see on race cars and even Teslas and EVs, stuff like that, where we can modulate how much brake pressure we get with the computer.
And one really cool thing about that is that I can change the brake pressure and the brake feel by the modes of the car.
So, if we can wire that in, that'll be really, really cool. But another thing is we're going to be eliminating all of the coolant up here. Now, usually this car would have three really big coolers.
There's one on each side and one in the front. And that is for the air to water intercooler. That's called the low temperature circuit. This is gallons and gallons of water plus the lines plus the pump. All that stuff is going to get eliminated completely and lower the weight of this car considerably. And we're also going to be putting the weight in the middle of the car because instead of this, we're going to be using the air conditioning system. Now, I'm going to go into that when we have more of those components on hand because I've ordered those components and they haven't gotten in yet. But I think honestly this is going to be one of the coolest science projects and experiments that we can have because not only are we revamping the look of this car and the weight of this car, but also the way the car cools itself because we're not only dealing with 900 horsepower, which the car would have come with stock. We're going to be dealing with about 1,400 horsepower. And that's just from the engine alone. So, we have to mitigate that. and we have to mitigate that in the Florida heat and humidity. So, I think we have a lot of interesting solutions there. Now, you'll notice that this car does have a subframe. It is powder coated, but there is a second subframe here that is also powder coated. That's because we have had a gift from the guys that I helped build the P1 for. Uh, they actually had a P1 subframe that they powder coated and they didn't need because they had an OEM tub from McLaren delivered to them. So now I have this P1 subframe powder coated and I'm going to be replacing this with this because on mine, even though we did a lot of repairs on the bottom, I don't know if you can see this clearly, but there is some corrosion happening on the aluminum. And that only happens because the salt water gets in the aluminum and then creates a process called electrolysis where essentially it just breaks down the aluminum, makes it really brittle, and then it just starts chunking off. Now, this is just an OEM subframe, and it looks fantastic. I will have to go through and tap all of the bolt holes because these act as grounds, and you definitely don't want powder coat on grounds because that's not going to act as a very good ground. So, we have to kind of make this into bare metal, but that's okay. This is going to look fantastic, fantastic with our new hydraulic lines and our new bolts. And when we put everything together, our new engine. I hope you guys enjoyed this update on my P1. I do have a lot of work to do on this and I need to get my hands dirty immediately because we still have stuff like the wiring harness and all the computers and then figuring out how that's all going to work. And I have been trying to solve those solutions at a billion miles an hour off camera. But if you guys want to see more sort of deep dives into how I solve these problems, let me know in the comments.
And uh I'll definitely make some more videos about it on this channel before I introduce that on the main channel with one big video where we have a big cathartic ending. But uh yeah, we need to wrench every day. I need to wrench every day and uh get my hands dirty. And I can't wait for you to see this thing run for the first
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