Raise your hand if you have designed and built a full size car…. Nobody? Doing so would be a huge task considering car manufactures have thousands of people involved with designing and building a car model. Eager beaver [Neil] has stepped up and taken on that challenge. He’s started an open source project he’s calling the CarBEN.
The plan is for the car to hold 5 people comfortably while being just a tad larger than a Scion xA. The body is made of foam and will be covered with fiberglass. The car is designed in a shape that tapers in towards the rear of the car and has features like a smooth underside and covered wheels to create a low coefficient of drag. The goal is for this beauty to get 300-400 miles per charge with an Miles Per Gallon Equivalent of over 224.
So far, the body is the only portion complete but that is still a pretty significant accomplishment in itself. [Neil] designed the car body in Sketch Up and then divided the model into slices. He used a CNC Router to cut each individual slice out of sheets of foam. Then those slices were glued together and the exposed edges sanded to make a smooth shape. The process is documented extremely well on [Neil's] site.
It appears the project has stalled a little or [Neil] just hasn’t updated the documentation of the project recently. Either way, we think this is a great project and look forward to seeing it progress.