The Lancia Beta Montecarlo, a mid‑engined Italian sports car produced in the 1970s and early 1980s, is regarded as a classic of motorsport design. In the 1990s, Pabrico was commissioned to create a polystyrene mould of this iconic model, which had been re‑shaped by a designer to improve aerodynamics and maximise performance on the racetrack.
To ensure absolute accuracy, half of the original car was delivered to our Seaford base. Even the smallest deviation could compromise its aerodynamic profile, so precision was critical, down to the fine grooves in the bonnet. We sculpted numerous individually shaped polystyrene sections, bonding them together to form the complete mould. Once assembled, the surface was coated with a water‑based two‑part filler and painstakingly sanded for hours to achieve a flawless, defect‑free finish.
With the mould complete, the designer applied multiple layers of fibreglass until the panels reached the required thickness. These parts were then fitted to real cars, and the process was repeated as fibreglass components were sold to other racing enthusiasts, bringing the Montecarlo’s enhanced design to a wider motorsport community.
