1. Full-scale arch profile shows that the concept will be unusually roomy while open.
2. The prototype was made from this male mold, because female molds take much more money and time to make.
3. Male mold receiving door-skin layer that will support the carbon fiber-on-foam shell layup.
4. Foil layer on the male mold will be coated with mold-release compound before resin and carbon fiber are applied.
5. Structural foam strips will be epoxied in place over first layer of carbon fiber.
6. Sanding the foam to the proper contour took weeks of work.
7. Applying the epoxy resin coating over the foam.
8. Laying a layer of carbon fiber over the foam.This required three people working together.
9. Applying resin over second of three layers of carbon fiber.The layers were vacuumed tightly together at 9 lbs. psi and baked at 145°F.
10. Popping the hardened outer shell off the mold. POW!
11. Cutting the shells to the right length and contour.
12. Looking at the profile of the second shell inside the first shell. Note the space (upper left) for the solar panel and satellite dish between the shells, protected from weather and theft.
13. Cutting the back windows, which allow see-through rear visibility for the driver.
14. "Kamm" tail profile cuts air drag and increases stability.
15. Installing the end panels in the outer shell.
16. Gluing some of the 14 drawers made of Finnish birch plywood and doorskin sides and bottoms.
17. Crude, full-scale mock-up of modules reveal the best layout. Carefully designed details accommodate small dimensional aberrations in the truck's cargo bed.
18. The finished kitchen module in Finnish birch plywood. Kitchen drawers are sized to fit common food packaging.
19. Shells in place with interior modules secured by 10 bolts screwed into Rivnuts® permanently installed in cargo bed's walls and floor. Furnishings can easily be removed to permit use as a cargo hauler.
20. Back triangles, folding stairs, door and door frame are installed for the first time. Finished at last!