The design of the cars and the examination of the cars built by Kevin Strong and Doc Watson had revealed a number of serious construction challenges above and beyond the normal difficulties of scratchbuilding. These challenges can be broken into roughly 4 broad areas - windows, trucks, clerestory roof and interior details especially lighting. In each case, a commercial product was not readily available and the fabrication of the required component was anything but straightforward.

This section shows how Phil has constructed a prototype kit and solved the inherent engineering problems.