2009 Ford Flex - Optical Illusion - Tech

Sean Smith used a styrene grading tool to obtain the correct shape as he blended the styrene and bumper.

The blue styrene was perforated with small gripping holes to help the Chavant modeling clay dig-in and adhere to the styrene. A dedicated sculpting clay tool was used to reshape the Flex's new front fascia. Casey began adding modeling clay to the front fascia.

After the front fascia was completed and shaved smooth, Casey laid out some of the special sculpting tools used in the process.

The modified front fascia was completed then shaved and blended smooth.

After receiving the 7-foot pieces of formed steel rocker skirts from JJ Metal Werks, they were mig-welded to the lower rocker panels. The formed steel rocker skirts lowered the rocker portion of the Flex body four inches.

To obtain smooth body panels Casey and Ron shaved the factory door handles. After removing the door handles, the pockets were patched and welded with mild steel plates. The plates were skimmed with body filler and then sanded smooth.

The Mocata Autosports team got busy applying mold release to the front fascia, rear bumper, and side skirt splash molds. The mold release will allow the new fiberglass parts to be separated from the splash molds.

A brush was used to apply the fiberglass resin mixture to the front fascia. Fiberglass resin was poured onto the fiberglass cloth, and then worked into the cloth with a brush.

The saturated fiberglass cloth was then draped onto the front fascia and worked onto the surface splash molds contour surface using a small pin roller, eliminating any air bubbles. The entire front fascia was covered with two laminated-layers of fiberglass cloth that actually makes up the splash molds backing.