Thanks for stopping by Bob , somedays it seams like Im spinning my wheels but the build is moving forward.
Don it's always good to talking about our builds. I really appreciate your suggestions and help.
For those following the build Here are the final shots of the front fenders and the front hood top painted. I'm very happy with the overall paint on the parts, only a couple mistakes. I'm hoping they wet sand and polish to a perfect finish to mold.
Thanks for looking Wayne
[This message has been edited by dobie1 (edited 04-20-2020).]
Due to the fragile nature of using foam in constrution ( very strong overall but breaks like a egg if dropped) and as Murphy's Law will happen both running boards were dropped. There is lots of fibreglass and bondo in the construction but a couple cracks did emerge in the flattop surface which was made and shaped using polyurethan foam. I repaired best I could wet sanding and filling , so hopefully I will not need to do too much sanding on the mold. I'm doing the two running boards first just because I do not want to have anything else happen before the molds are done. Each running board is made up of 3 separate removable flanged sections. The following photos show the upper and lower mold build. I'll do the third today.
this shows the planning of where the parting lines are.
this is with the flanges being attached
This is with the gelcoat applied , I use a silica additive to the gelcoat around the edges to ensure of hard and detailed edges. [img][/img]
top mold 3 layers of 1 1/2" mat I added reenforcement after this shot and 2 more layers of mat.
this shot is the bottom mold fab with the flange removed from the upper mold preping I used clay and molding wax to ensure sharp parting lines.
this shot is with gelcoat added as before.
this is with 3 layers
this is the finished bottom mold with reenforcement added and 2 more layers of mat.
I hope to finish this mold today enjoy and stay safe. Wayne
I've been busy finishing off the first running board mold.
I had to do a bit of a repair to a flange as there was a couple flaws that were easy enough to repair and would give me a better seal if I decide to do a vacuum bag.
then I applied the thickened gelcoat in the 90 deg corners to help the matt lay tight, after it kicked I applied a full coat of gelcoat.
I completed all the fibreglassing on the area so that mold is now completed, one down 7 to go.
I started the second running board finishing the top first. I changed up the flanges this time I covering them in aluminum tape. I found on the first mold even though the wood flanges were sealed that the wood grain came through more prevalent than I wanted.
Thanks for looking Wayne stay safe
[This message has been edited by dobie1 (edited 05-02-2020).]
First off thanks Shem ,lots of work but rewarding.
I got the second running board mold finished , I spent some time finishing all the parting lines then sealing and polishing the surfaces. They are now all buttoned up and put away to finish curing for a couple weeks.
I moved onto the next set of molds , there was foam used in the construction of the door and to avoid any damage I'm onto door molds.
I'm using a new material in the flange construction , 8" aluminum flashing. It gives me enough material to attach to the part and still leave a wide flange surface for vacuum bagging.
I got to use my gel coat cup gun for the first time
works pretty good and is way faster, it possibly uses a bit more gel coat but hopefully has a better finish.
this is with 2 layers of 1 1/2oz mat . reenforcement tomorrow and 3 more layers.
A bit of a update for those interested in the molding process. I got the first of the door molds finished today the build came together pretty quickly 3 days from start to finish. I'll leave the plug in for a couple days for the fibreglass to cure a bit more. I liked using the aluminum flashing for the flanges, it made forming some of the complicated transitions easier to build. It requires a bit more caution until you get to shooting the gelcoat, the release is very easy. I also really enjoyed how fast and easy it was using the cup gun to lay the gelcoat down in a uniform layer.
This is with the reenforcement glassed in , I'm using water pipe foam insulation attached with hot melt glue to make the reenforcement works best working with the different contours and angles.
This shows the nice wide flange area for vacuum bagging.
Gel coat shot and ready to lay the glass
This is the completed mold , i'll trim it up tomorrow.
On to the next one!!
stay safe everyone Wayne
[This message has been edited by dobie1 (edited 05-13-2020).]
Again, keeping in mind that I'm sort of "old school"...and really don't keep up with modern day methods/techniques/materials much at all, but when doing "production" molds, we generally made them about 10 1/2 layers of ounce and half matt, over at least two coats of tooling gel as the actual mold "pulling" surface, backed by a coat or two of "tracer" gel, which could also be and usually was, tooling gel also. Used tooling resin to do the layup, but only did about 3 1/2 layers at a time.
If you are doing the molds, just so you'll have a source for replacement parts for your own car, what you've indicated using here will be more than sufficient, in my opinion, but if you are wanting to get multiple pulls from the molds, you might consider making them a little thicker. You could use some core matt over what you've already got, then a few more layers of regular matt on top of that, that's what IRM did with some of the molds they made back in the 90's, and they are still usable today. Most of what determines how well, and how long a mold lasts, is how well they are maintained and that proper prep steps are used with each pull from them.
The aluminum flashing & furnace tape I've used with great success many times. What you've got looks impressive!
Not trying to give "advice" here, you certainly have things well under control and don't need any comments from the peanut gallery, just trying to share a little of what I was taught, and learned through experience.
As I said, what you've got looks fantastic and should serve your purpose for as long as you need them to. Outstanding work, and thank you for sharing your progress, it's much appreciated by all, I'm sure.
Keep up the stellar work and keep plugging away at it! I, for one, am looking forward to watching you take the first parts out of your new molds...that is always a very satisfying experience for me. I'm relatively certain, it will be for you as well.
Thanks Bob, never started out as a teacher I'm learning all the time from builders like you and Don O . Sage and many others. IF someone can pick up something new to try the hobby will grow.
Thanks for the positive comments wftb ,as you have probably read from the post by Sage whom I respect and agree with unless I put a lot more money into my molds there will only be a limited number of bodies I could produce " possibly 10 " if I look after the molds properly.
Sage , I agree the they should be beefed up but I calculated I would need to invest a bunch more money and I'm getting some real blow back from my wife on the money I've spent recently. When I started this project I was still working making a good income as a Pilot but I've been fully retired now for 5 years and money is running out for my project. I never started this project to sell kits ,I just wanted my own car , the project has morphed over the last 4 years with the possibility of building a kit ,I have been contacted by a few guys' I do have one guy in Oklahoma that wants one but I think he is on the fence now as I haven't heard from him, probably too do with the pandemic and money flow from his business. So my focus is now to build and finish my own car , I'd like to get it done sooner than later . Having said that I really do appreciate your mentoring and passing on your experience, its very much appreciated.
I've started building the mold for the hood, I'm planning on doing a resin infusion carbon fibre hood to cut the weight down.
stay safe everyone
[This message has been edited by dobie1 (edited 05-15-2020).]
It's been a busy 10 days both working on the car as well as work on installing solar panels on my roof for the pool.
I completed the centre fill for the fenders ,it worked out great nice doing a small mold.
I then moved onto the passenger fender ,after a lot of studying the contours and angles I decided I needed multiple parts to the mold ,a seam down the middle of the fender to ensure I would not have problems pulling the parts.
these show the fairing compound into the tight corners to help the fibreglass transition the right angles.
Gelcoat sprayed on next step to apply the fairing to the corners.
Thanks for stopping by stay safe Wayne
[This message has been edited by dobie1 (edited 05-31-2020).]
That one appears it was a little extra challenge. I get analysis paralysis doing things like that. Every step is one more closer and some more.
Hi Sourmash Yea it was bit of a challenge only 3 more molds and the front will be finished. Leaving only the rear half , I'm working on a plan to build a rotisserie type setup to be able to mold at different angles.
these shots show the fender top done and reenforcement added, I'll flip it over tomorrow and do the wheel wells and and underside parts. This will weight a lot so it going to be a bi__ch to move around by myself.