Full-size models-Production of models

Full-size models
A full-size clay model is begun when the scale model has been satisfactorily modified. It is constructed in a similar way to the scale model but uses a metal, wood and plastic frame called a buck.
 The clay is placed on to the framework by professional model makers, who create the final outside shape of the body to an accuracy of 0.375 mm. The high standard of finish and detail results in an exact replica of the future full-size vehicle .

This replica is then evaluated by the styling man-agement and submitted to top management for their approval. The accurate life-size model is used for further wind tunnel testing and also to provide measurements for the engineering and production departments. A scanner, linked to a computer,passes over the entire body and records each and every dimension . These are stored and can be produced on an automatic drafting machine. The same dimensions can also be pro-
jected on the screen of a graphics station; this is a sophisticated computer-controlled video system showing three dimensional illustrations, allowing design engineers either to smooth the lines or to make detail alterations. The use of computers or CAD allows more flexibility and saves a lot of time compared with the more conventional drafting
systems.
At the same time as the exterior model is being made, the interior model is also being produced accurately in every detail (Figure 1.17). It shows the seating arrangement, instrumentation, steering wheel, control unit location and pedal arrangements. Colours and fabrics are tried out on this mock-up until the interior styling is complete and ready for approval.