chestikoph1

Sheds done and finally getting a chance to play with fibreglass again. I have been a little distracted with another car project but in between I’ve selling a few of front lips I have been making. I got asked a few times for a boot spoiler and wasn’t keen on selling the large version I made so decided to make a smaller easier to post version and one that’s a little more subtle. Similar process as before, and it’s almost ready to take a mould. Shame these plugs end up getting destroyed! Looks good in the funky blue topcoat.

A little progress, have ended up with a combo of wide body and flare type. I have progressed a little further than this but haven’t taken any more photos yet and every thing is in storage as I empty the shed for the new one. Also painted the new boot/spoiler combo.

And so it starts again!! Until I start accumulating all the consumables for infusion I thought I would make a start on the wide body. Narrowed it to two styles, bolt on flares, kind of like what I am already running but boxier/wider. And full wide body arches trying to follow the cars body lines as much as possible. I thought I would start with the front and try the full wide body option first. Doing this on the spare guards I have as this gives me the option to return the car back to normal at anytime and let me enter a couple of events coming up. Gonna have to take my time unfortunately with this stage as I’ve got a home/shed renovation happening soon. Couple of pics to help my ideas make sense to everyone, similar to the way I did the boot spoiler, get the general shape sorted, fill the voids with the foam blocks and then start shaping.

Well this first project is done. Managed to replicate the result successfully and also make the spoiler section by itself. For this second one I trialled some 3 mm Corecell as a core and got rid of one layer of glass. Turned out super strong and light, actually way stiffer and lighter than the factory metal one. 2.9kg v’s 5.8kg for the factory one, and perfect as a pin on option, no need for the frame or any other reinforcements. Spoiler option also turned out great, had to add in some bolt recesses to allow it to be an easy bolt on fit. Vacuum pump and catch pump have arrived and looking at buying some carbon fibre and consumables for an infusion trial soon. First need to make a new mould and thinking of either doing the bonnet or maybe the boot lid as a first go. Boot is small and not a huge loss in materials if it goes pear shaped. Unfortunately I can’t use the current mould as the flanges are a little small and being 2 piece mould probably too complicated for a first go. So that’s it for now, until the next update take care, stay safe (and sane) for those of you who are lock down affected.

Yeah super happy with the finish of the gel coat, if it wasn’t for the join line of the 2 piece mould you could have left it with out paint, like they do on boats I guess.

Yeah the whole infusion process is looks like the ultimate way to make composite parts, strength, weight and also aesthetics if you’re into the carbon look. I don’t know if that would suit and older car but I will take the weight reduction, if I do the bonnet, boot, doors, front and rear quarter panels there is a heap of weight to lose. Haven’t ordered a catch pot yet, I was thinking of making my own. I have seen some simple DYI ones made out of pvc pipe. Anyway after 2 months of dust and resin fumes… whats do you guys think? needs colour but all in all pretty happy with the final result and knowing it’s somewhat unique is pretty cool.

I have enjoyed the process of design, concept and then manufacture, seeing the fruits of effort is rewarding, The fact that it’s built from scratch is pretty cool. I did weigh the original boot lid. It was 6.1kg, it’s actually rather light, I guess it only small. I will weigh this one once it’s done though. I don’t think it will be much lighter, being layered up with chopped strand matt it does take a fair bit of resin to wet out. This first one is more about learning, styling and to see if it gets rid of some lift. I’ve ordered myself a vacuum pump to trial resin infusion next. A carbon or even fibreglass resin infused one without the metal. (Just the skin) would weigh less than 2 kilos I think, I would attach it via pins and also get rid of the hinges which are very chunky, between them and the boot lid maybe lose 10kg? some reinforcement before I glue it up

Getting the frame ready to bond to the new skin. Something that surprised me was the weight of the frame, its about a quarter that of the outer metal skin, I was expecting the opposite. It’s made from much thinner steel, I guess the moulding gives it its strength.

First spoiler/boot lid in one gel coated and laminated, I will give it a couple of days and demould. Not the easiest to lay up with the deep spoiler section but all went ok. Really looking forward till its cured. In the meantime I will start separating the original boot skin from its frame, idea is to bond this one the original frame. Although the end goal is to make one of these or similar in carbon fibre and secure it with pins to the car. This one has always been a learning opportunity and to get my mould making process right.

Mould prepared and ready to go, polished, waxed and with a coating of PVA.

Well the plug released from the mould…but not in one piece unfortunately. It stuck around the back corners and had to be broken to release, in hindsight I should have used PVA not just release wax but I was trying to gain the smoothest finish possible. Positive thing is the mould turned great and should be ready after a 1200 grit sand and polish.

Mould done, give it a few days to cure and then hopefully it releases from the plug with no issues.

It’s primed and sealed. No more bog, only taken a month to get to this stage of making the plug!! I am finally done with filler, i think it’s as symmetrical and straight as it’s going to get. Key take away, next time keep it simple with flat surfaces. I think I went to complex making it with compound curves and trying to follow the cars profile too much Anyway it’s done, final sanding to 1200 grit to go and then it’s ready to pull a mould from it.

Classic!! That would double as a nice luggage rack. Perfectionism, it’s a terrible affliction, probably borderline OCD. My thing is if I wouldn’t be happy paying for the finished product, then it’s not good enough. Getting close to blocking and final shape, pics soon.

More filler and sanding!!