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 Fibreglass prototype fabrication

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Coss



Posts : 13
Join date : 2013-11-11
Location : Wellington

PostSubject: Fibreglass prototype fabrication   Tue Feb 18, 2014 7:23 pm

Hi guys,
I wanted to try and knock up a fibreglass headlight fairing to hide my dash away - I've never tried, but it looks relatively straight forward (famous last words!).

I was wondering what to use to build up the prototype?  I assumed some sort of hard foam I could use to cut/sand in to shape but for the life of me I can't find any suitable products.

Any ideas?
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tavita



Posts : 16
Join date : 2013-11-18
Age : 54
Location : Wet Harbour, Auckland

PostSubject: Fairing   Tue Feb 18, 2014 7:48 pm

Hi mate.

Go visit a couple of building sites close to where you live, as most floor slaps nowadays are constructed with polystyrene pods. There's always plenty of offcuts blowing around the site and the thickness should be about what you need. Otherwise building supplies sell different thickness's of poly, you'll just have to buy a whole sheet though.
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Coss



Posts : 13
Join date : 2013-11-11
Location : Wellington

PostSubject: Re: Fibreglass prototype fabrication   Tue Feb 18, 2014 7:54 pm

Ahh so just polystyrene blocks like what you'd use for underfloor insulation you mean? (for example)
Then shape it with an electric knife?

Hmmm there's a thought!
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Woody
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Join date : 2010-04-26
Location : Wellington

PostSubject: Re: Fibreglass prototype fabrication   Tue Feb 18, 2014 8:25 pm

Just one thing about polystyrene there Coss, Once you have shaped it you will also need to seal it otherwise as soon as you start applying the resin your pattern will start to disintegrate. ( ever pored petrol on poly  pale )
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Cletus
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Posts : 25
Join date : 2013-01-08
Location : Dorkland

PostSubject: Re: Fibreglass prototype fabrication   Tue Feb 18, 2014 8:45 pm

On the plus side the mix makes poor mans napalm for some guy fawkes fun
 Twisted Evil 
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Woody
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PostSubject: Re: Fibreglass prototype fabrication   Tue Feb 18, 2014 8:54 pm

Must remember that one Cletus . Wink 
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tavita



Posts : 16
Join date : 2013-11-18
Age : 54
Location : Wet Harbour, Auckland

PostSubject: Fairing plug   Wed Feb 19, 2014 5:40 pm

The floor slab poly pods are 1200 x 1200 x 230. The poly balloons which make up the pods are about 2 to 5 mm in dia but it would be good for a start, shaping by cutting and sanding etc, you can always tidy up with bondofill. Iv'e done this a few times in the past when making small panels for vehicles. Woodys right , you'll have to seal it, couple of coats of acrylic paint then glad wrap has worked ok for me. The plug gives you the basic shape to build your fibro on, if your after a reversed plug like boat builders use then that's another story. Cheers
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De Ranged
Apprentice
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Join date : 2013-05-19
Location : Napier

PostSubject: Re: Fibreglass prototype fabrication   Sat Feb 22, 2014 12:14 pm

If you find shapeing it a bit agressive use plaster instead of bondo its alot cheaper and smooths up real nice its what most companys use
I got told a tip the other day for a very cheap and release agent.... blastard pain killers for my back stuff up my memory... if I remember I'll throw it up
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PostSubject: Re: Fibreglass prototype fabrication   Today at 4:51 pm

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Fibreglass prototype fabrication
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