ArcticShell Invention (1994)

In 1994 along with another student attending school "Aviation Engineering" in Thunderbay Ontario Canada, we decided  to do our third year project on an invention we had dreamed up! An enclosed snowmobile using the latest composite technology. We started with a wind tunnel prototype which we tested at Lakehead U. Once a final design was agreed upon we started to build a plug for producing a mold which was made from plywood and polyurethane foam. When the plug was completed this had already consumed the allowed time for the project and was assumed by everyone that this would never become real! I was extremely determined to make this project a reality. I rented a garage in 1994 where I was staying and began construction of the necessary tooling to make a real ActicShell which is what we called it! After completing the tooling (molds) we were convinced to take them to a FRP molding shop locally. This was a really bad idea . The result was a complete loss of the molds from lack of proper prep and care for a green mold and was cooked by the so called molder. Every dollar into this tooling and close too 2000hrs labor had been lost. Ground zero. We pick up the pieces and repair the plug to make another master tool. This time we laid the first part ourselves and was molded to perfection almost 6mo. later. The first prototype was now in existence. After making the hardware and mounting it to a 1994 Actic Cat Jag 440 we began testing the new design for real. It was very surreal! After increasing interest we applied for a patent which was then granted on the design. At this point my colleague had fulfilled his interest in the project and was not interested in continuing a business venture. I began producing shells for costumers in the US and Canada. The total number of Shell produced was 18. The design was now outdated and it would be time to invest in more tooling $. I had just recovered most of my money and couldn't stomach another huge loan. I have never built another Shell to this Day. There must still be some running around out there of one which I recently discovered on E-bay. I never kept one for myself and really regret this since it was one of the coolest thing I have ever done in my life! Below are pictures and  soon video. I will keep updating them as I find them and scan and capture some old video from original testing on VHS. Enjoy!

ArcticShell Inc.

Windtunnel Moldel	Windtunnel Model
Starting plug Construction	Plug Construction
Plug Construction	Plug Construction
Plug Construction	Plug Construction
Spraying Foam coating	Starting Shaping
Tired of Sanding	Sit Down Sanding
Sanding Crazy	Shaping Up
Pay attention to detail	Ok now for the other side
Looks pretty good?	Plug VS Dash 7
Air scoops are so Cool	Rain or shine sanding
Ok... sun would be nice!	Ready to glass
Ready to glass 2	First layer of glass
Sanding in first sow!	Fill and sand
No fingerprints by now!	Top coat
End of school term	Continuing in own shop 2nd layer
Ready to make mold from plug!	Laying up mold gen1
New mold Gen1	Inside the new mold
The very First Part!! s/n001	On a roll s/n 001 and s/n 002 gen1
First Gen2 longtrack with side flares s/n 003	Ready to Ship S/N003
Gen 2, S/N 004 and S/N 005 in forground	S/N 005 with 004 in background
S/N 004 or 005 ?????	S/N 004 or 005 in crate
S/N 005 being born!!!	First prototype Gen1 s/n 001
First prototype Gen1 s/n 001	First prototype Gen1 s/n 001
First prototype Gen1 s/n 001	First prototype Gen1 s/n 001
Recently discovered S/N005 Feb3/2010	Recently discovered S/N005 Feb3/2010
Recently discovered S/N005 Feb3/2010	Recently discovered S/N005 Feb3/2010
Recently discovered S/N005 Feb3/2010	Recently discovered S/N005 Feb3/2010
Recently discovered S/N005 Feb3/2010	Recently discovered S/N005 Feb3/2010
Recently discovered S/N005 Feb3/2010	Recently discovered S/N005 Feb3/2010
Recently discovered S/N005 Feb3/2010	Beautiful Patent!
Patent Page1