Flyer Front End Design
Improve.
Revitalize.
Modernize.
Flyer 60
Given the task of designing a new hood for the Flyer 60 I had three main goals in mind. I wanted to revitalize the front end to be more in line with current Flyer designs. I looked to improve the overall visual into a more cohesive and complete look. And I wanted to bring some more modern components into the vehicle like new headlights to help bring the design forward.
Cardboard
Created cardboard mockup to ideate surfaces, panel positions, and to shape the hood around pre-existing component space claims.
Sheet Metal
We then translated the cardboard into sheet metal to get a rough fit and see how to best adjust and attach the design to the vehicle.
Final Fit
After various iterations and redesigns, we fit the finalized sheet metal for the Flyer 60 hood. From there it was onto final paint and assembly.
Flyer 60 | Final Images
Flyer 60 in Rubble Covered Street (Background Generated with AI)
Flyer 60 at IDEX 2025
Flyer 72
After a successful showing with the Flyer 60 we moved onto creating a new front end for the 72 inch wide varients keeping in the same visual language. Having learned a lot from the process of construction, fitting, and design of the sheet metal, we moved onto CAD to design the new front end.
Cardboard
For the Flyer 60 we had a shorter timeline on the initial mockup and had built up the cardboard on the vehicle itself. The Flyer 72 version had a longer timeframe and we were able to work out the sheet metal in CAD to use as a base for the cardboard patterns.
Sheet Metal
After some adjustments from the cardboard fit, we ordered sheet metal panels to be cut and bent. The initial test fit went much more smoothly this time around with only minor adjustments being needed.
Final Fit
This was the final test fit of all the adjusted sheet metal panels on a more finished vehicle as opposed to a bare chassis. At this point all adjustments had been made and it was ready for disassembly, painting, and reassembly for testing.
Flyer 72 | Final Images
Flyer 72 on Dirt Road
Flyer 72 with Helicopter
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