Prius 75-91mpg

[Nathan jones]

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[Nathan jones]

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[Nathan jones]

5am Finally out of the mold...
So it went, thin gelcoat, gelcoat mixed with car paint, 200-300csm with 80% resin 20% car paint. Takes alot longer to go off with paint but I hope to just cut and buff....

Also some polymer test pieces. Spunbond polypropelene, 180gsm spunbond acrylic, 180gsm polyester and melt blown polypropelene. I figured that might come out on top because of the size of filaments. The best by far was meltblown and polyester resin (net composite weight 0.92g cm2), followed by acrylic with epoxy and improved flex. I have found some rare meta aramid in Japan I will also test once I can get it (very different to those). Thinking of my front bumper that broke up inside. It's still fine but only held in place by a layer of glass I included. The carbon is just too brittle for things that occasionally flex or have vibration, over time all the fibres break

...also the blue and black is wax and mold release on the bumper...the surface is quite nice for how my stuff usually comes out..

[Nathan jones]

bumper costs..including mold. Where it's likely less than I round up to .50p. Most items bought in bulk

Resin 3l £24
Glassfibre £2.02
Wax £.50
Brushes £2 I now just use a silicon spreader
Cellulose £.50
Gelcoat £12
Dust sheets£.50
Autopaint £.50
Trim plug £3.66
Polystyrene£1.63 I would use 20mm next time and spray foam in corners..
Acrylic adh £.50

parts total £47.81

Labour 9h £165
Total £212.81

n.b + .50p PVA mold release
**likely another 2-3 hours more trimming/fitting to go..

[Nathan jones]

Well instead of making a door mold at xmas I had to go shopping, do cooking and see in laws so productive totals for the holiday came to 0

although I did finish work early today and sand off the outer layer of gelcoat. It did not go as white as I expected and will need spraying but in sort of good news weight did go from 4.5kg to 3.8. Still double the plan

Also a couple of xmas presents, enough resin for 4 molds and doors (£58), a spare inverter to restore and the last few days mpg. A 160 mile trip (50-60mph) then round town stuff. Surprised me, I was expecting high 70's as it's 10c (and no heater). E5 99, also the gearbox and engine (0w-20) have just been serviced. Lastly ordered 12v heater that will fit at the exhaust part of the battery air system. When really cold it will send warm air from underneath before trips.

Hopefully I can take a few days off next month for molds, I don't have spare doors so it's time tricky

Incidentally the bumper does still smell of thinner and styrene so it may go lighter, it's been in a dark cold part of the garden. Also I only use .09% catalyst to give me an hour or so layup time...

[Nathan jones]

Didn't have much in the way of parts except cardboard and a spray can lid..but it worked the way I expected.

The heater is not that hot, 50-60c with about a cpu fan speed...

After 10 mins was above freezing. I only did 10 mins in case the computer picked up a large difference in temps but it did not. At one end the batteries were hotter so the air is taking the short route, I will remove the upper sections and install a cone filter with a valve sending the air downwards. Car worked much better and the ice was off by the end of the road. Not quite as good as 10-15c but much improved with the usual springiness. Most frosty days will see ice on constantly. The car 12v could also be used as the separate battery had plenty of life left (2hrs at 9a officially).

Toyota did not install a cabin filter, a 3.5" cone will help the oem fan as after 10-15 years they are always clogged up not cooling the batteries.

Also the bumper is sprayed, I will cut and buff in spring once it's properly dry

[mrme1983]

A new door I made but it did not come out right. The mold spread by a couple of inches and it's so strong it could not be changed, prestress would not be so good (was in a hurry and forgot mold bracing).

You can see how the steel door is more curved. I will post more once the next one is complete

Could not login on my old account

[mrme1983]

I am using sandwich panels on the next one. I managed to salvage some composite beams, the lock and hinge area and the plexiglass

[mrme1983]

I don't think this deserves to come under the 'advanced vehicle mod section', a 300k repair 'new steering angle sensor' job while re-mantling I did not replace the steering wheel balance weight or buttons

Maybe I should have waited and reconditioned the electric power steering motor and pinions at the same time....