During their 25-year collaboration, Kelly Farrell and Steve Wales never worked on a project as massive as the giant yellow monster taking shape at ACI Composites in the Greenfield Industrial Park.

The sculptors — from Lititz and Millersville, respectively — along with their helper, Brian McSurdy of Strasburg, have been working since November to give form to "Miles the Monster," the official mascot of Dover (Del.) International Speedway.

The cartoon sculpture, which will stand 46 feet tall when completed, will be the centerpiece of a new fan zone being built at the NASCAR track, known as the "Monster Mile" for its treacherous driving conditions.

"Miles the Monster" will be one of the largest fiberglass sculptures in the United States.

"It's like a big puzzle where the pieces don't fit," Wales joked.

ACI Composites, a custom fabrication shop in East Lampeter Township, was awarded the project in late October, and the sculptors started making the chicken-wire form for the beast in November.

Miles will be depicted bursting out of concrete atop a 7-foot "Wall of Fame" base listing all the NASCAR winners at Dover.

The sculpture will be visible from Route 1 for anyone heading to the Delaware beaches this summer. All one will have to do is look for the monster's two large glowing red eyes.

Farrell and Wales began by making a 4-foot scale model of the final sculpture.

Miles was being fabricated in sections inside ACI's shop and has been taking shape outside since January, including his 60,000-pound steel armature, or skeleton. When fully assembled, he will hold a 600-pound model of a full-size NASCAR race car and be able to withstand 120 mph winds.

"We sculpt a small one and make it big — miniature to monumental," Farrell said.

The monster's armature is being covered with yellow foam insulation and carved into the desired shape with grinders and electric chain saws.

Fiberglass eventually will be sprayed over the foam to preserve its shape. The final step will involve spraying a material over the fiberglass to give Miles the look of being made of concrete.

If maintained properly, the builders say Miles could last more than 50 years.

Dwight Miller, owner of ACI Composites, said his company mostly does architectural pieces, such as cornices and columns, but the firm has also worked on other large-scale projects.

ACI built the dome at Sight & Sound Theatre, constructed Hershey characters that stand outside of Chocolate World and created a 26-foot-tall figure of AC/DC lead guitarist Angus Young that went on tour with the band.

However, Miller said his company has never before attempted a project as massive, unique, challenging and fun as Miles. He said the builders also have had fun.

"Sometimes you look out and you wonder if the Three Stooges are working out there, and the next time something falls together and you say 'Wow, that really worked,'" Miller said, laughing.

Outside of ACI Wednesday, the trio of workers listened to Neil Young's "Tonight's the Night" on the radio while bolting the enormous steel right arm into place.

McSurdy, who started working for ACI in November, tossed nuts and bolts up to Farrell and Wales as they worked. Farrell yelled "Thank you" each time he caught an item.

A huge NASCAR fan who watches every race on Sundays, McSurdy said he was excited when he learned he would be working on the project. He has been welding, lifting pieces into place, spraying foam and learning the sculpting trade from Farrell and Wales.

"It's a once-in-a-lifetime opportunity, really," McSurdy said. "There won't be too many more jobs like this coming around."

The sculptors expect to have Miles completed by the end of the month. Then they will take it down — cutting it into six pieces — and transport it to Dover.

The monster will be ready for unveiling in Dover on May 14, with NASCAR driver Jeff Gordon taking part in the ceremonies.

Farrell said the project has faced some major challenges, including a tight schedule, but he said it's been exciting.

"This is the biggest dancing cartoon I've done," he said.

E-mail: myoder@lnpnews.com