DTSFab.com (Desert, Trail and Sand)
The Machine Shop => Fiberglass/Composite Fabbin' => Topic started by: fabr on April 14, 2009, 09:36:23 PM
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Just a start.More info and pics as it develops.
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It does work well, Tho has to have a coating to prevent resin from eating it... For small projects it works great.. They have a white polymer foam that can be sanded and then primed, No need for Shellac or bondo etc... The white shit is ungodly expensive tho...
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blue and gray also. It is extruded styrene foam. Resin will melt it if not coated with a barrier before applying resin. I have had less than good results from DW mud tho.
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Keep posting Master, I have never done much with fg so I am watching with interest. If time ever allows I would like to do a rear cover/shroud on my car. Time will tell.
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A bit more work done and beginning of hood plug.
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Fabber, what are you cutting it with, I had a cheap ass wood band saw, and that sucker cut that foam so sweet...
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Rough cut is done on a cheapass band saw also. Actually my cheapass bandsaw has too shallow a throat but my larger and not so cheapass one did the trick. All other shaping has been done with a piece of 1.5" 4130 dropoff with a piece of PS file paper on it. Gotta use cromo ya know for good results! LOL!!! The other tip/trick I'll give is to use a concrete magnesium float with a piece of PS paper on it also for the shaping/filing to shape. The convex shape allows for glass flat shaping without edges digging in. I'll post pix tomorrow of the low buck tools.
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I about forgot to mention that I laminate the extruded foam using MINIMAL expanding spray polyurethane foam.Spray the foam on the part,let rise for 5 minutes,push parts together and spread the foam around. It will go to liquid and be an excellent adhesive. Weight or clamp foam pieces overnight to cure. The PU foam will try to expand a slight bit till cured but that is a good thing since the voids will be filled in at the same time. If you look at my pix closely you will see where I broke that rule.
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That is looking like it will be very appealing to the eye as well as functional. As dunebound said. Keep posting. Im learning as well!
One thing though. I see radio location but where is the 8 track going to go ;D
Great work! keep it up!
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That radio is the 50 watt base to car to car radio and the in car intercom unit. I'm trying to make this car as "upscale" as I can. I've done tons of FG work but I'mm trying to step up to the next level with this one.It will ultimately be the wifes car. This is just prep/practice work for the mid-engine V-8 that comes next.
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Were does the tupperware tray go? :police:
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LOL!!!! 8) ;D Funny you should ask tho .There is quite a "trunk"area in front of the passenger.
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That radio is the 50 watt base to car to car radio and the in car intercom unit. I'm trying to make this car as "upscale" as I can. I've done tons of FG work but I'mm trying to step up to the next level with this one.It will ultimately be the wifes car. This is just prep/practice work for the mid-engine V-8 that comes next.
after seeing one of these setups in person on chris's and marks rails I do believe I will have to invest in one myself. the guy with the northstar v-8 rail is now a dealer for them, by the way ;) ;) I am going over there tomorrow night.
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A fair chunk of money but the enjoyment level of being able to communicate is well worth it IMO.
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A fair chunk of money but the enjoyment level of being able to communicate is well worth it IMO.
Yes - best thing you can do for both passenger fun and safety in groups....
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Call me stupid. But what is "PS paper"?
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Pressure sensitive sandpaper.I use 60 grit for roughing in a shape. just an FYI, paper WILL get dull sanding the stuff.
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Due to the foam being a bit "distressed" LOL!! I need to skim coat the whole plug and do final sanding.Before I use PVA (poly vinyl acetate) primer on the foam both as a barrier coat but also to ensure full adhesion to the foam of the flowable body putty used for the skim coat. Here it is before skimming.
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well,hell that didn't show up too well.Better pic tomorrow.
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3 pix of the hood in early stages. For this piece I rough in using a 3 1/4" electric plane and the concrete float with PS paper on it. Fricken foam dust and shavings EVERYWHERE!LOL!!. Glad I got a schoolboy hired that does cleanup.He's gonna LOVE tomorrow. ;D ;D ;D
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Thought I'd post up what the results of a little test.I have for years used PVA primer to get good adhesion of the flowable body putty to the foam. I had read recently though about using it as the barrier coating to keep the FG resin off the extruded polystyrene foam-EPS. EPS will melt with polyester resin on it. I had always in the past used clear shellac for this purpose with great results. Anyway I considered using the PVA this time .FORTUNATELY I had the sense to do a test run first. I learned a long time ago to treat all info on the web-this site excluded of course ;D ;D ,to not trust info without verifying for myself. Here are pics of the results. Plain pink foam with a big melted spot in 3 minutes. White PVA primed-melted much less but totally unacceptable in 15 minutes. Pink foam with shellac showed no signs at all of loss of shape after full cure. I'll stick with the shellac. 8)
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Are you building plugs then moulds then parts? Or are you going to glass the foam for a one shot part?
Will these parts fit someone else's Rorty design, or did you modify it so they will only work on yours?
If you want to sell these parts, please make sure you apply with the management of this site before trying to slip in any free advertising. You have been warned.
;D ;D ;D
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Are you building plugs then moulds then parts? Or are you going to glass the foam for a one shot part?
Will these parts fit someone else's Rorty design, or did you modify it so they will only work on yours?
If you want to sell these parts, please make sure you apply with the management of this site before trying to slip in any free advertising. You have been warned.
;D ;D ;D
Plug,mold,part.
Only works on mine.-
Oh and EFF the management.Oh,hell,I guess that means go eff myself too! Damn. ;D ;D ;D
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Actually the dash part would be pretty universal if the frame width was right. Yours is plenty deep along the top, so it could be trimmed for a different windshield bar arrangement.
How wide is it overall? ;D
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haven't measured. 50ish inches tho.
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It's 51.5" at widest point.
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Any more progress pics for us students of the glass?
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I'll have a few in a day or 2. This is being done in the "spare time" between a couple of other projects.
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I understand that. I shelled the trans in the rail, got it pulled and Shane is in the process of building it.
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I'm watching closely! I want to try building a hood for my car... I'm learning!!!!!!
Nice work so far Fabr! :)
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So far.......... ;D ;D
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Well I guess it's been a day or 2 now. ;D ;D you know me.Always running behind or something comes up needing more attention than I want to give it! ::) ;) Anyway here's a few pix to show the dash ready to cut out gauge cluster,GPS and radio locations. The dash is done in a moldless method.
First step was the foam buck or plug . The pink thing in the previous pix. It has to be made a bit undersize to allow for FG thickness as you add layers.I used 2 layers of 3 oz. mat for this purpose.That gave a part approx .070 thick.
Due to the fact that i used the same pink foam as I used 4 years ago BUT I failed to notice the density now is less the buck was a bit "soft" and would fingerprint easily so I had to skim coat the plug with Bondo.That necessitates sealing the foam from the bondo.Styrene foam will melt in the presence of bondo or polyester FG resin.
So now I sand plug to final shape,fill defects and sand to near perfection(a bit of an ego thing! ;D). Next step is to apply 4 coats of high build polyester sanding primer.I use Featherfill by Evercoat. Stuff sands to perfection with no pinholes and is very predictable.Next step is to repeat last step as many times as it takes to get it right.
Now we wax the plug with 4 coats of high temp mold wax.Buff to polish.This step is not really critical for the moldless part but makes plug release much easier. I also tried a new to product from Fibreglast that is a water based mold release.Just mist it on and that shit will RELEASE nicely!
Now lay on a layer of resin.Don't worry it will separate on the plug and not stay spread out. You're only putting it on to give the mat something to grab and stay in place while wetting out the mat with additional resin.Use enough to fully wet but don't get carried away.Too much is just as bad as not enough.
Smooth out the mat as well as you can.Much better to spend time now instead of sanding it later.With modern mats it's pretty easy to lay it on smoothly. Repeat with another layer of mat and wetting.
Let cure overnight.Do not remove the plug too soon as an incompletely cured part will sag and get out of shape.Don't want that now do we? LOL!!!
After plug removal I used 1 layer of non woven polyester core material to underside of dash to add stiffness. Whole dash is 5 pounds.
I think it turned out pretty well. YOU can do the same! Just a bit of practice and the use of modern materials have made composite work much more pleasat than 40 years ago when I built my first canoe at the age of 13.LOL!!!
I think I'll start a thread about the amazing changes that have come about in just the last 4 years.BEFORE anyone buys any supplies let me post up the info and the source of the best FG man I have ever known.
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Damn! Mastr has skills!* Nice job. mm:
*None of them inter-personal skills, but we can always hope.......
WTF is that smite button???????
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Thank you. I appreciate that.
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Damn! Mastr has skills!* Nice job. mm:
*None of them inter-personal skills, but we can always hope.......
WTF is that smite button???????
Kansas doesn't have many bushes to beat around.We just get right to the point. Less BS that way!
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That is gunna be BITCHIN! When are we starting on mine! ;) ;D
Git that list up! I'm goin shoppin'
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Looks great Fabr...
Cup holder? ? ? ? ? ?
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You got your sub enclosure made for that stereo hole you have there ;D
Looks dam nice, that takes some time.
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LOL!!!! You already have a dash!
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Buggies are never done. Just in a state of evlolution.
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Naw,it's just on to the next project for me.Once done they're done for me. I'm already planning the "big un".
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That looks awesome, thanks for sharing. The amount of knowledge between this site and the "other" one is amazing. A person could learn just about anything they needed to about buggy building by reading through all the post, and sorting through some of the BS ;D.
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The BS is site flavoring! ;D ;D
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Any more progress pics Master? ie side panels, gauges install etc. Its lookin good.
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Masters buggy might be "naked" :o ;D :o
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Gotten sidetracked trying to get the VMC sorted out.I'll post some more pretty soon tho. Gotta get a move on! ;D Got too many irons in the fire really. :-[
Now there is a comment I can empathise with.... how the hell do you proritise? Its got me fooked (specspeak) ???
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Masters buggy might be "naked" :o ;D :o
rather his buggy than him..... :-*
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Masters buggy might be "naked" :o ;D :o
Time before last my nephew and a buddy rode through the campsites with nothing on but a couple of thongs underwear that they got from my wife. Tnhey were cutting donuts and wheelies and all kind of shit and then came the park patrol. They chased them onto the dunes and got away but it was about 45 degrees and they had to hide out in the dunes at night for about 6 hours before they wers safe to return.Them boys had some hard,pointed nipples for sure and you could hardly tell if they had any manhood left-shrunk smaller than a golf ball!
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Now there is a comment I can empathise with.... how the hell do you proritise? Its got me fooked (specspeak) ???
Mostly I just chase myself in circles and as things get finalized they just fly off from centrifugal force and get replaced with new stuff.Never ending chase.
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So did your jewels thaw out or fall off after your 6 hour ride? :) :)
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Wasn't me my man! I'm WAY WAY too clod blooded for that.
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I think you protest to much ;D ;D ;D ;D
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Tell ya what-next time it can be enemy,ds,doug h,myself and you. We can scare the hell outta the campsite and GET A FREE TOUR OF THE JAIL ;) ;D
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I don't think Barney Fife down there would know what to do with us. Thongs are legal. But just so long as we get it on video for the site! ;D ;D ;D 3: 3: hh: :m :n
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6 thong clad guys...
motorized picnic table....
cooler full of beer...
OH MY GAWD.....
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I'm already emBAREassed!
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I don't think Barney Fife down there would know what to do with us. Thongs are legal. But just so long as we get it on video for the site! ;D ;D ;D 3: 3: hh: :m :n
I beg to differ.The county jail is not bad.Don't ask me how I know.
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I beg to differ.The county jail is not bad.Don't ask me how I know.
SSSOOOOOOO.....AHHHHH.......MMMMMMMMM
How you know Fabr :P
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Shhhhh!!!!!!!
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Barney was waiting at the gate some 6 hrs later.
Glad your in spec
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Barney was waiting at the gate some 6 hrs later.
Glad your in spec
;D
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Not exactly.
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I'm not donning no thong...but I will drive the table and run the camera...And post bail if I have too 8) ::)
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ThoughtI'd post a rear view pic of dash just laid poorly in place. You get the idea.
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You going to have that ready for October?
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WEll it looks like it will be all done but for the most important part -the 091 to busa mating. Still an outside chance but I fear there's been too many distractions and business commitments to get that done in time but I WILLbe ready for the next time. I'll bring the buggy just so you guys can pick it to pieces and make all the "suggestions" you want. I do value you guys opinions. Oh well ,I'll still be there riding the quads and having fun. It should be a blast for all! Sure was last time.
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WEll it looks like it will be all done but for the most important part -the 091 to busa mating. Still an outside chance but I fear there's been too many distractions and business commitments to get that done in time but I WILLbe ready for the next time. I'll bring the buggy just so you guys can pick it to pieces and make all the "suggestions" you want. I do value you guys opinions. Oh well ,I'll still be there riding the quads and having fun. It should be a blast for all! Sure was last time.
Better have the belts in it and the tires on. Won't need paddles. I'll use my long tow strap so's not to get Mrs Faber to sandy. bounce
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I'll bring my extension! Heheheheeee Speaking of tires. What's peoples preference for dirt tires,front and rear in the 31" tall range for a buggy of my size?Approx 1300pounds or so. Maybe. Hell I have no real idea of the weight tho yet.
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I'll bring my extension! Heheheheeee Speaking of tires. What's peoples preference for dirt tires,front and rear in the 31" tall range for a buggy of my size?Approx 1300pounds or so. Maybe. Hell I have no real idea of the weight tho yet.
Dreamer Dreamer Dreamer
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:m :m :m What about a tire suggestion? ;D
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Ok,OK, maybe 15-1600?
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:m :m :m What about a tire suggestion? ;D
Goodrich Buckshots PR 78-15LT 31 inch tall They fit a 6 inch beadlock.
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Talking front and rear?
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Talking front and rear?
Rear. They have a mite smaller one to run on the front. Would need to call my dealer and see what he has in a 28 inch tall one for the front.
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I'm running 31" tall fronts.
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I'm running 31" tall fronts.
Yes but. They are smoothies or razor. Much lighter. Put a 31 tall knobbys on and they tend to get heavier.
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Enough heavier to make me go narrower/shorter with the trade off being a bit ,just a bit, less ability to handle obstacles..
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Enough heavier to make me go narrower/shorter with the trade off being a bit ,just a bit, less ability to handle obstacles..
Won't be no narrower. Just a little shorter.
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front
Size:30x9.50R15/C 104S Sidewall:RWL MSPN:51612
Rear
Size:31x10.50R15/C 109S Sidewall:RWL MSPN:87961
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Just a scoosh narrower. Not much.
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Now that sounds good.
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33X9.5X15 front BFG AT
33X12.5X15 rear BFG MT
Step up to some real tires.
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May well do that.Just looking for some suggestions.
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BFG makes a 33/10.50/15 in the MT. That is what I put on the back of mine. I am car powered but just a little heavier. Up front I have 5 rib ag tires about 29 inchs tall like a 6.50 15.