Although Fineline's Multiax 5 axis router could have made it in one piece, the Chevy had to be designed to split into elements small enough to be fitted into 747 air freighting containers - and it also had to be completed in just two weeks to make the deadline.
Fineline's Darren Wring comments, "Making the prop itself was a relatively straightforward request and that's exactly what we're geared up to do. It was the seriously short timescale and the fact that it had to be designed to be broken down for freighting that were the challenges."
Made from standard density polystyrene blocks, once formed, the Chevy front - weighing 100Kg - was then spray painted candy red with silver flecks mimicking the model's original classic colour. This process was completed in a car spray booth with cellulose paint after being coated with polyester body filler and plaster.
Fineline also fitted it out with a fully-working set of headlights and side lights.
Once completed, the Chevy front was flown from Fineline's base in Bristol to Hawaii where it was assembled by Wave Marketing's crew for the event.
(Jim Evans)
