Upper body-shell panels
The body of the vehicle is best described as an energy absorbing shell, constructed from polycarbonate panels. They work with the frame to resist impact intrusion, much like a natural skin. The precise tint, color, and polarization of the panels vary with customer preference. These panels are secured to the frame with aircraft grade mechanical fasteners, rivets, and in some instances with structural adhesive, and are constructed by cutting out the two-dimensional patterns from a flat sheet. A brake is used to add any bends, as necessary.
Except for the windows, the panels are laminated with a single layer of sailcloth, which is affixed to the inside surface and creates a soft touch interior, also helping to increase the overall stiffness of the body panels. The lower (shown in blue) and forward (yellow) outer-panels span the side of the frame. The front upper (violet) is composed of two or more joined panels, and is constructed from relatively clear polycarbonate, so as not to obstruct the forward command of the road. It provides two primary functions; to improve aerodynamics and direct wind to the sides of the vehicle, and it also serves as the upper door channel. The upper rear panels (shown in red) are designed to wrap around the top, allowing natural light to fill the interior.
Windows
The top window is cut from a single sheet of polycarbonate, which is bent twice. It is attached to the rear panel with a riveted lap joint, and attached to the frame along the sides. The front portion of the upper window panel has a single layer of flat glass affixed on the outer surface, for wiper-wear. The glass is sealed to the polycarbonate, and sealed from the elements all along its perimeter with mastic. Similarly the rear window consists of a polycarbonate panel.
Structural floor
The floor is constructed from a foam-sandwiched carbon-fiber lay-up. It is rigid and strong, so as to provide significant strength and stiffness, in order to mount the seats, and resist crush during collision—in order to protect the occupants during impact. It is fastened directly to the frame, and has a profile that helps direct air under the vehicle, and absorbs energy from impact. It also functions as an intrusion-proof wall in the front and rear.
Due to its translucent polycarbonate architecture, the vehicle body-panels themselves can light up, and thereby function as a brake light or turn signal indicator, as shown.
