Quote:
Originally Posted by Bicycle Bob
Sure, you could build a surface of wood or foam splines, and 'glass over the outside to hold the shape, and then do the inside to get a sandwich-core part. That way, you don't have a mold left over. The weight savings from the core will probably disappear into filling and fairing the surface. The wood core would want expensive, hard to sand epoxy, so the urethane foam sounds better, if you can handle it neatly. Using a thick build-up and then removing the foam is also a valid proceedure, but it tends to require more fiddling around the details. Fortunately, it is very easy to add bits to a 'glass part.
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You guys are honestly about a 2 leagues above me with this stuff.
Ok. Let me throw this at you for a procedure, and you tell me if it'll work.
1) Build up a foam block by gluing together a bunch of sheets of foam insulation
2) Cut away excess material until the block is the same shape as the fibreglass part i want to make
3) Sand the crap out of it
4) Coat the foam block, with wax / release agent / something to make it not stick to the fibreglass
5) Put on 5 layers of cloth/resin. I think the Canadian tire stuff is all waxed.
6) Separate part of block
7) Sand the crap out of the part
8) Paint, mount, and enjoy increased fuel economy
9) ?????
10) Profit
Only thing i don't have worked out in my head, is how to mount it after it's done that dosen't involve punching holes in it. Somehow it seems wrong to go to all the effort to get a professional looking cover, and then put a screw through it.
The Canadian tire kit comes with 1L of resin, fiberglass mat, and hardener.
You (bob) seem to indicate that if i don't have enough, i can go out, buy another kit, and add layers. Did i get that right?