2013 Subaru Impreza WRX STI - Project Log

[Xist]

Originally Posted by UltArc

I lined it with newspaper and painters tape, taped the paper into place, filling the lower grille, then taping the sides and ends down. I then did the same with foil. This was painters tape.

I couldn't say what failed, but the whole thing was just a mess. I am currently working with the foam carefully, and it is alright for filling the gaps my mirrors made.

I think the biggest mistake was to use a lot of foam at once, and fill the openings. I am being much more sparing now, and it seems like it is alright.

I tried to be conservative with my foam, but with my fog light cavities, I think that I should have only used a little at a time, even though it would have taken much longer that way.

If I ever actually purchase a Civic HX, I would want to make a Kamm-back, even if I did not end up using it. With that, I could cover the area with marine plastic, tape it down well, build foam-board walls, seal the edges with Great Stuff, and then pour expanding foam into the cavity. Trying to sculpt fifteen or twenty square feet sounds like a nightmare!

[jedi_sol]

Originally Posted by Xist

Did the 'Stuff absorb the resin, or did the resin melt the foam?

Is there a difference?


I did a quick search because I remembered that there were different types of resin and foam and that some work together and others do not. I remember someone putting resin on his foam and it melted the outside a quarter-inch or so. Anyway, have you read this? http://ecomodder.com/forum/showthrea...oam-21668.html

I have not read that thread yet. But after reading it, it confirms that what happened to me was that the resin got absorbed because "Stan" said that "...foam-in-a-can is urethane, which once cured does not dissolve in resin...or gasoline, or pretty much anything else."

The reason why i think the foam "aborbed" the resin is because i know there were definately pockets of foam with varying thickness, and as i was laying up the resin, i could see the foam get slightly warped from gettind damp from the resin.

I've used polyester resin/great foam in the past with my Del Sol Aux Light plug, so i know the combination did not have any major issues.

Anyways, had a wedding this weekend so i couldnt finish my grill block. I'll try to finish it up this week and post pictures!

[jedi_sol]

finished the wedding, i had my grill block all perfectly sanded to exactly how i wanted...the double sided tape idea worked great because now the fiberglass molds EXACTLY to the shape of the grill.

Then I tried to remove the fiberglass from the actual grill ....thinking that painters tape and foil will easily peel off of the grill.

NOPE! i guess over time, the painters tape and the double sided tape become more sticky for some reason...the fiberglass foil WOULD NOT separate from the double sided tape without lots of force...

well this happened


luckily i was able to salvage it with smaller patches of fiberglass and bondo

[UltArc]

Originally Posted by jedi_sol

finished the wedding, i had my grill block all perfectly sanded to exactly how i wanted...the double sided tape idea worked great because now the fiberglass molds EXACTLY to the shape of the grill.

Then I tried to remove the fiberglass from the actual grill ....thinking that painters tape and foil will easily peel off of the grill.

NOPE! i guess over time, the painters tape and the double sided tape become more sticky for some reason...the fiberglass foil WOULD NOT separate from the double sided tape without lots of force...

well this happened


luckily i was able to salvage it with smaller patches of fiberglass and bondo

Something similar happened to me...

I hope the lessons you are learning will help others. Thank you for taking the time to post it, keep us updated, and help spread knowledge & experience.

[Xist]

JediSol and UltArc, I am very sorry about both of your experiences. Do you have any idae how one could prevent that?

JediSol, I hope that you have easier going from now on!

[UltArc]

Originally Posted by Xist

JediSol and UltArc, I am very sorry about both of your experiences. Do you have any idae how one could prevent that?

JediSol, I hope that you have easier going from now on!

I think small amounts of foam at a time, and using say, a cloth, then lined with duct tape may work.

[jedi_sol]

Originally Posted by UltArc

I think small amounts of foam at a time, and using say, a cloth, then lined with duct tape may work.

or maybe perhaps use a "weaker" double sided tape... or use smaller strips of double sided tape so that they do not form a super strong bond....or use more layers of fiberglass so that when you pull off the fiberglass, the fiberglass will be strong enough to retain it's shape

In all honesty, i couldve prevented this if i strenghthend the fiberglass with an extra layer of resin or an extra layer of fiberglass.

[jedi_sol]

To salvage the grill block, i just decided to trim the grill block back an inch so that it sits flush in the grill vs. covering the edge of the grill.

Not too shabby!


Sits more flush now




A LOT BETTER THAN V3.0


Next up...just need to fill up some tiny holes (because im a perfectionist) and then paint!

[jedi_sol]

I was at pep boys getting some oil for an oil change. I decided to swap out my old kill "switch" and replace it with a brake switch.

I decided on brake switch because it's normally closed - push-to-open...all in one motion. On my old switch, after killing the engine on long coasts, i sometimes forget to switch it back on to bump start the car.

I also made a basic "bracket" out of coroplast to hold it in place.






EOC-ing is A LOT more streamlined now

[jedi_sol]

After 3 months of driving and carefully monitoring the engine temps, the engine temps show no change at all whatsoever (80% lower/100%upper vs. no-upper-grill-block-at-all-when-i-was-building-upper-grill-block-v3.1)i decided to make a slightly larger lower grill block. Plus i made the grill block out of one piece of coroplast.

No more buck teeth!

Before:



After: