A New Zealand Aston Martin fan is 3D printing his own replica 1961 Aston Martin DB4.

Auckland-based computer programmer Ivan Sentch is spinning up a replica DB4 piece-by-piece on a 3D printer that costs around $500. His blog, Replica DB4 Project chronicles the process – and the problems and pitfalls he’s faced – since starting the build late in 2012.

 Sentch says he’s completed about 72 per cent of the body printing, which will then be used to create a fibreglass mold, and build the final body onto a custom-built spaceframe with power coming from Nissan Skyline GTS innards currently being used in his Ferrari 250 GTO replica. The Ferrari, by the way, will get a BMW V12 engine as consolation.

Sentch says his decision to do the Aston Martin was prompted by family needs. “It was partly because I need four seats, and the 250 GTO kit car I've got hardly gets used as it's only a two-seater and I can't take the kids in it,” he says. “But also because an old Aston Martin is very very cool and a DB4 over a DB5 or a DB4 Zagato because I just like the look of the DB4 more -- I'm going for the no bumper GT lightweight look, though.

He says the wheel track of the Skyline made it the ideal donor car for the Aston Martin DB4 project. “It had the right wheel track to fit in the body -- wheelbase doesn't matter as you can get a custom propeller shaft -- it's a six-cylinder like the DB4, and the Skylines are very cheap.