On some projects we use our router for only small bits of the whole. A current project, a small dump truck built over a golf cart chassis is a perfect example. The routed portion of the project will be limited to an emblem on the grille and a dimensional sign on each side. It’s not much compared to the whole thing but it adds just the same.
As always it starts with a drawing.
A new frame was built around the old one. The new body is built around this steel frame, leaving the original aluminum one intact. In this shot I’m testing the new seating position.
I then welded a pencil rod framework to shape the new body. Expanded lath was then tied to this framework.