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My Fiberglass Front With Pop Up Headlights


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#16
strudel

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I am very interested in the process. How does one get from the cardboard version to this?


Is the fiberglass attached to the cardboard which makes a mold? I have a couple of small projects in mind but need some direction. How about a full view picture of the front end? I have a fiberglass bumper for my CRX but need to cut the marker light area larger to install a better unit than it was designed for. Nothing fits into their designed aperture so I am using a Prelude fixture which needs enlarging and shaping the area to fit. JS


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#17
arvieg

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wow some really good fabrication

#18
andrew

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QUOTE (strudel @ Sep 2 2009, 06:38 AM) <{POST_SNAPBACK}>
I am very interested in the process. How does one get from the cardboard version to this?


Is the fiberglass attached to the cardboard which makes a mold? I have a couple of small projects in mind but need some direction. How about a full view picture of the front end? I have a fiberglass bumper for my CRX but need to cut the marker light area larger to install a better unit than it was designed for. Nothing fits into their designed aperture so I am using a Prelude fixture which needs enlarging and shaping the area to fit. JS

hi
basicaly when you get the ribs shaped to the curves you want
you then glue flat card over the whole lot ensuring you follow all the ribs
then you put parcel tape over all of it
then the fiberglass goes on top of the tape
the fiberglass doesnt stick to the tape
the nosecone on the car is the master which will have to be smoothed and painted and then a mould is made
hope this helps
regards andrew biggrin.gif
heres a few more photos of some more layers of fiberglass
and the basic holes for the indicator sidelights have been cut for the austin metro units






Edited by andrew, 02 September 2009 - 05:26 PM.


#19
strudel

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Thanks Andrew,

Just so that I am perfectly clear on the process please confirm my reply. After applying packing tape to all the cardboard you lay cloth and resin onto the cardboard. Let it set and then remove it from the cardboard as it doesn't stick. This then is shaped into a nice smooth finish on the outside or inside? This becomes the master for making the mold.

So how much thickness difference do you have to build into the cardboard for the resin and cloth so that it doesn't become higher than the area it has to mate to? Or is it the inside of the fiberglass that goes over the cardboard that becomes the mold shape. Sorry, but I'm not tech savvy in this area. JS

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#20
Gant

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QUOTE (andrew @ Sep 2 2009, 05:17 PM) <{POST_SNAPBACK}>
hi
basicaly when you get the ribs shaped to the curves you want
you then glue flat card over the whole lot ensuring you follow all the ribs
then you put parcel tape over all of it
then the fiberglass goes on top of the tape
the fiberglass doesnt stick to the tape
the nosecone on the car is the master which will have to be smoothed and painted and then a mould is made
hope this helps
regards andrew biggrin.gif
heres a few more photos of some more layers of fiberglass
and the basic holes for the indicator sidelights have been cut for the austin metro units


thats a good idea, the packing tape over the cardboard... im used to making custom speaker enclosures using aluminum foil then about 3 layers of blue painters tape covered in turtle wax/mold release

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#21
andrew

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QUOTE (strudel @ Sep 3 2009, 01:36 AM) <{POST_SNAPBACK}>
Thanks Andrew,

Just so that I am perfectly clear on the process please confirm my reply. After applying packing tape to all the cardboard you lay cloth and resin onto the cardboard. Let it set and then remove it from the cardboard as it doesn't stick. This then is shaped into a nice smooth finish on the outside or inside? This becomes the master for making the mold.

So how much thickness difference do you have to build into the cardboard for the resin and cloth so that it doesn't become higher than the area it has to mate to? Or is it the inside of the fiberglass that goes over the cardboard that becomes the mold shape. Sorry, but I'm not tech savvy in this area. JS

js
you smooth the surface on the outside of the fiberglass that has
been applied to the cardboard that has the tape on it
then you paint it and polish it and apply release agent...this is the master
next you put more fiberglass on
this is the actual mould
then you remove the mould and its smooth on the inside
you then polish it and apply release agent
then you put in gel coat,, let it harden then the fiberglass in the mould
then you pull out the panel
hopefully it comes out in one piece
hope this helps
regards andrew
it takes a lot of time

#22
firstgencrx

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Andrew,

I just love the way you think. It never ceases to amaze me how much talent is on this forum. cool.gif

David
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#23
giraffe

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wow, sweet.

wish i had the ability to do that.
to poor for rice.

#24
Gimpalot

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Where's the updates on this? mad.gif
QUOTE (Sinic @ Apr 21 2010, 09:47 PM) <{POST_SNAPBACK}>
You really know you have made it far on rpr when someone quotes you in their signature. I can't wait for the day!

#25
andrew

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QUOTE (Gimpalot @ Oct 19 2009, 10:23 AM) <{POST_SNAPBACK}>
Where's the updates on this? mad.gif

sorry its been a while since i posted about the nose cone
heres the latest photos
i wont be doing any more on the front for awhile
as i want to progress the si type spoiler
thanks for you interest
Andrew


Edited by andrew, 26 October 2009 - 05:58 PM.


#26
84b18

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im sure that will help performance a bit, even mpg. but you should add a splitter.
Oh, you don't know if it's legal?
you're in california of coarse it's ILLEGAL!!!!!

#27
MrDisibility

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QUOTE (firstgencrx @ Sep 4 2009, 01:05 AM) <{POST_SNAPBACK}>
Andrew,

I just love the way you think. It never ceases to amaze me how much talent is on this forum. cool.gif

David



+1

#28
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Looks good so far!

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#29
DallasCRX

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Any updates?
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#30
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WoW! Interesting work, I'm gonna keep an eye on this topic smile.gif

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