Bronco scan project
A full size Bronco was digitally scanned then turned into a 3d model. Once we had a computer model it was cleaned up then scaled down to one third it's original size. After that the model was sliced in half allowing it to fit on our 5 axis CNC router table. When both halves we complete, the Staff Shop took over. They proceded to do the finish detail and assemble the two halves. A mold was then created over the foam tool and a fiberglass shell was created. Several units were fabricated for different scenes of the movie
In the Ferry Boat explosion video clip below, it should be noted that this Ferry was back in service carrying passengers within a couple days after filming. No Ferrys were harmed during the production.