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Lightning McQueen #1

After years of people looking at our Tow Mater replicas and asking "Where is Lightning McQueen?", we have decided to take that step and build him.  Now lots of people have taken red sports cars of various makes/models and applied decals like Lightning has, but we are going to actually build a correct replica - from scratch - not using an existing car to start with.  In fact, we started with the original Lightning McQueen, using 3D scans of the one at Disneyland California.  

Using these scans, we sliced the car like a loaf of bread, and built each of the pieces individually out of wood, then reassembled them back into the "loaf" again.  

Once we settled on the correct size (actually 10% larger than the original to make it big enough to resemble a real car), the wooden sections were covered in a string mesh, and the corners were sculped from expanding foam.

The body is then covered in burlap soaked in plaster of paris; which is then covered in drywall mud to allow us to continue shaping the perfecting the body.  The custom made "Lightyear" tires are now coming together as well - big 295/65-15s wrapped around 15x10 Aero Nascar wheels.

Then about 12 boxes (42 gallons) of drywall mud were slowly spread over the burlap, allowed to dry and layered again.  Hours of sanding to get a pretty good shape going.  Windows were laid in place to build the recessed openings for them.  Then this layer was sealed with polyurethane.