Apis_Mellifera
Apis_Mellifera Reader
6/9/14 9:01 p.m.

I have an extremely rare fiberglass body panel that I need to copy. I've borrowed it under the provision that I do nothing to alter it. It has old, crazed paint on it and is cracked in a few spots. I've done a few experiments with painter's tape and drywall compound and have been able to protect and repair the part such that it is reversible.

Now I want to produce a mold so I can produce a finished part. Ideally it would be reusable to make six or so. I have never worked with fiberglass beyond patching small sailboats. Can anyone give me a specific shopping list of materials (gelcoats (wax, no-wax?), resin mat/fabric, etc) and brief steps on what to do. I've internetted and read books and have formulated a plan in my mind, I just need a real-world quick how-to.

For example, I put the release agent on the part and apply gelcoat (I will brush it on). It should be non-waxed so the following layer of fiberglass will stick...right? If I wanted to get a nice surface on the repaired part so I could pull the mold, I'd use waxed for that so it cures...right and then apply release when I'm ready to make the mold?

Trans_Maro
Trans_Maro UltraDork
6/9/14 11:23 p.m.

Get some tire valves to glass into the mold as you build it up, make sure the rubber sits down against the body you're working from. This will let you use a bit of air blown in between the two parts to help them release.

I've made molds from fiberglass parts (imsa flares for 2nd gen Camaro) and even using the nice, PVA mold release it can be an absolute bitch to get the master to release from the mold.

Not something I'd want to be doing in my spare time unless it made me an absolute E36 M3load of money.

Shawn

Curmudgeon
Curmudgeon MegaDork
6/10/14 7:59 a.m.

The V12 Jag in the MGB thread shows using aluminum foil to protect the body panel he pulled a mold from. Here's a video showing the same procedure:

http://www.youtube.com/watch?v=5hq0EemgJGI

Sonic
Sonic SuperDork
6/10/14 8:10 a.m.

Look up West System epoxy. Very well regarded in the marine world, extremely versatile, and their website is a huge wealth of knowledge on usage and techniques and how to.

fasted58
fasted58 PowerDork
6/10/14 8:21 a.m.

There's tons of fiberglass and mold how to videos on YouTube. Think I once spent an entire winter watching them. Some of my favs were of a guy building building miniature battle tanks, he did an incredible job and it all carries over to automotive work.

DaveEstey
DaveEstey UberDork
6/10/14 11:41 a.m.

This guy does a lot of automotive fiberglass how-tos https://www.youtube.com/channel/UC2eM7ZuCPfXTAgbKOpuIaIg

motomoron
motomoron SuperDork
6/10/14 5:22 p.m.

I've done ~a lot~ of this, and it's easy, but you have to be absolutely methodical and you cannot cut any corners. Obtain real mold release wax and real mold release compound, modeling clay (plasticine)tooling gel coat, light cloth, mat, resin, cups, sticks, release wedges, gloves, acetone, lacquer thinner, and lots of paper towel.

For supplies I like these guys

Clean and buff the panel very well and apply 3 or 5 coats of release wax. I'm not kidding. It doesn't take long and you won't regret it. Cut out all the pieces of mat you'll need to end up w/ about 1/4" thick layup. For stiffening I use pieces of mailing tube split in half on a band saw, or wood - 1x1, 1x2. If the mold has "sides", you'll form dams with lots of modeling clay, lay up the mold over these dams, then removed them, wax and release the inside of the mold you just made and repeat the gelcoat and layup on the side of the part and onto the adjoining mold. Drill holes for 1/4" bolts before releasing the mold sections from the part.

Apply a coat of mold release - I used to spray it but I usually use a pad made of old, soft T shirt and gently rub on a light, wet coat. let it dry.

Mix your tooling gel coat and using a wide, cheap "chip brush" lay on a thick, wet coat. You want a film thickness of 1/32", maybe more. Thick! The gelcoat is what picks up the fine detail and makes a hard, durable inner mold surface.

As soon as the gelcoat is cured you can begin laying up mat and resin. I usually put out a line of 10 oz paper cups of resin and use a hardener dispenser so I mix a cup, which only takes a minute, pour, roll w/ a laminating roller, dab w/ chip brushes into corners and around edges, and when the cup is mostly empty, catalyze the next one and work continuously.

(Laminating a 5 x 7 foot tail section for a race car takes hours and resin kicks in 10-15 minutes tops)

It is critical that the lamination to the gelcoat has no voids or bubbles! NONE!

I'd probably let the first layer set up most of the way before continuing to avoid heat buildup induced distortion from a thick laminate's exothermic reaction.

Once cured, use a jig saw and cutoff wheel to trim most of the excess around the perimeter. Then start with the wedges at a corner - usually a couple wedges and the mold just pops of easily.

I've had a whole car nose exit the mold with a wee tug. It's all in the prep.

A good book on the basics: Composites: Aird

Strike_Zero
Strike_Zero SuperDork
6/10/14 8:50 p.m.
DaveEstey wrote: This guy does a lot of automotive fiberglass how-tos https://www.youtube.com/channel/UC2eM7ZuCPfXTAgbKOpuIaIg

Wow . . . He makes it seem so easy . . .

DaveEstey
DaveEstey UberDork
6/11/14 7:19 a.m.

In reply to Strike_Zero:

Yeah he does

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