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Gallery: Building PAC Version 2 (2008)


Mouse over for caption, click to enlarge.

PAC2 concept sketch
Chris\'s CAD drawing of PAC2
Chris\'s CAD drawing of PAC2 - Front view
Maybe we can use tractor inner tubes for the wheels!?
Making a quick fiberglass and plywood rim to test the tube
Testing the tubes for the first time, hauling over tree-root obsticle
Testing hauling tubes loaded up with expected 200kgs
Test of fabric wheel cover from blue tarp (will be bullet proof Kevlar) to make tubes puncture resistant
Chris turning up PAC axle parts on late
Chris and Clark sewing Kevlar cover for PAC tyres
Chris cutting the aluminium load arms for the PAC
Chris and Clark with their bullet-proof kevlar wheel cover
Clark sewing up first prototype Kevlar wheel cover
Close-up of Kevlar wheel cover fabric
Cutting bolts on wheel hub to save weight
Chris and Clark assembling their wheel hubs
Clark holds up a newly assembled wheel hub
Clark hacksawing aluminium load arms for PAC2
Our rubber-clamp joining system to hold axle onto frame
Clark filing the spacer bar between the load arms
Chris welding up a section of the PAC
Chris circular-sawing a length of the aluminium load arm
Getting there - PAC 2 frame so far
A dirty little chimney sweep
Clark and EMP guys watching the first test rim infuse
The resin flowing down and infusing into the rim mould
Clark pumping up the tire on the test rims
Looking good! The test rims are the perfect shape!
Check out how well 2 half rims stack together for shipping!
Holding up PAC with tent set up
Clark looking inside tent on PAC
Clark painstakingly stitching together netting
Chris drilling holes for netting attachments
Clark and Chris testing netting for PAC 2 design
Lachlan from EMP spraying the gellcoat on the rim mould
Carbon fibre cloth wrapped around the rim ready for infusing
Chris cutting out bolt washer rings from sheet of carbon fibre
Clark sewing hem onto test fabric for PAC2
Chris blowing up the wheel around the first rim
Clark crouched beside the first completed wheel for the PAC2
Clark tying the fabric flooring onto the PAC frame
Chris hooking on the material skin that the tent will sit ontop of on the PAC.
Chris\'s sister Sarah posing on the completed PAC fabric cover
Chris holding up a completed PAC2 axle with finished wheels
Clark with our first semi-completed PAC2
Chris hauling the PAC2 with about 220kgs of load ontop (including Clark)
Clark lazing back in the bag-netting, sipping a mug of tea
Clark hauling the PAC2 along the road - nice EMP sticker there on the rims!
Clark hauling the new PAC along the road
Chris testing to see how the new carbon/kevlar rims made my EMP flex under load
Clark hauling the PAC2 over rocks at Avalon Beach
Clark lashing the PAC2 onto the roof racks
PAC2 frame with Kevlar/Carbon wheels beside it
Chris hauling PAC2 over rocks
Chris hauling the PAC2 over some pretty serious boulders
Testing our cart and gear in -38deg C warehouse freezer
PAC2 with tent ontop
Chris holding up the cool little Asus Eee PC laptop in the warehouse freezer
The laptop, video camera and bear alarm working at -32.8 deg C
Clark showing the PAC2 - netting for bags underneath, silver fabric over the top for the tent to sit on
Stick tries to poke into PAC2 wheels as Chris hauls past
Clark wading PAC2 through swamp
Tent set up ontop of PAC2
Chris hauling PAC2 along 4wd track
Clark hauling PAC2 into the distance
Chris sewing Kevlar covers for PAC2 tyres
Tripple row of Kevlar stitching on Kevlar PAC covers
Chris testing if the PAC2 floats in Avalon pool as Discovery Channel film
Chris and Clark explaining our fancy rims to Discovery Channel film crew
Chris welding together last bits of PAC2 frame
Chris hauling PAC2 towards the Discovery Channel film crew
Us with our composite rims and carbon hard tops
Our carbon-fiber hard-top for the PAC2s
Clark spray painting our PAC2s
Stabbing PAC2 tire with screwdriver
Chris and Clark working on sponsor logo banner
Chris putting sponsor banner on PAC
Clark hosing down PAC2

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© 2007 Chris Bray & Clark Carter