Matt:The body panels are 7/16 poplar and are flexible enough to conform to the curved body frame members. The curved subframe and runners are laminated oak, glued and clamped into shape. The struts are oak and are through mortised and tenon into the cross members and runners. The front dasher is 2 layers of 1/8" plywood which was flexible enough to fit into the curve.Marc: I had an old one that was rotted out and was missing many pieces but gave enough for patterns and all the iron parts we needed. The runners are the only new iron on the sled. Other than the wings it was great fun to build and the wings were not all that bad except I was getting pressed for time. I had not worked on it for about a month due to other job comitments and then all of a sudden when the boss came back they all got excited about getting it finished in time for the company Christmas party. It will have a stuffed deer hooked to it with sleigh bells and a red nose and then sit in front of the bosses house for the Christmas season.
The sleigh goes to the upholstery shop Monday morning. It was painted this week and the irons installed so it can leave Monday. The paint job was done by the painter for the trolley company and is a dark metalic blue base coat clear coat. The iron and trim is a silver gray. The upholstery will be a cadet blue which is a light blue gray. I will post another pic when all is completed. The wings were the toughest part of the whole thing. It took three attempts before I came up with the right form and then had to make a right and left mold. They are made of laminated poplar and are glued and toe nailed to the outside of the runners. Oh by the way it has $700 worth of paint on it,that's more than I paid for my first 4 cars combined.:9