Reproduction steel AE86 body shell. Both Levin and Trueno version will be available. Currently in development. These bodyshells are being recreated piece by piece and the painstaking process likely has a few more years to go, but here's the story.
 
Each original piece of a donor AE86 is 3D scanned and carefully modeled in 3D CAD software. This model is then used to make stamping die sets. These start out as rough castings from the foundry that pours huge quantities of steel into the approximate shape of the 3D CAD model. The casting is then machined on a huge 3-axis CNC mill that carefully cuts the surface down the precise level and shape dictated by the CAD model. After this the die still needs hand finishing to tune the angles and curves to perfection. This is slowly done with basic abrasives and a deep understanding of how details in the die translate to slightly different details in the finished part. The details of the oreintation of the part has to be incredibly well understood and exicuted so as to predict how the metal will flow when it is pressed and how it will spring back when the pressure is released. Thus the shape of the dies is different from the shape of the part.

Once the male and female die have both been made they can be tested and some parts are stamped and critiqued and the dies go back to the workshop to be adjust and tweaked. This process repeats until the sheet metal coming out of the press matches the original part, at which point the part can finally go into production.
 
Stamping is just the first step of producing a part. After stamping the part goes to a 5-axis CNC plasma cutter that precisely separates the part in the middle from the flashing around the outside of the sheet. Most parts of the car are not just a single stamping, however, so several parts are typically placed in a fixture and spot welded together, mimicking the process originally used to weld AE86 bodyshells together decades ago. These subsections are available to buy on our website as they become available in the slow process of recreating the entire car, and as soon as all the pieces are ready, complete unibodies will start rolling off the line.
 
This process is painfully slow, and as such it will yet be several years until we can ship you a complete bodyshell. However, we will be accepting preorders so you can ensure your place in line. These bodyshells are made in the same facility that has been driving the classic Muscle car reproduction sheet metal market, so you can be confident in the quality and workmanship. We also intend to produce our own bodyshells to tighter tollerances, as well as offering options such as seam welding, roll cages and suspension pickup-point modifications. 

Keep an eye on our website and we'll keep you updated!