The Zetec 'Ropacane

[surfguitar58]

I can’t weld worth a damn, but I love fiberglass, and you sir, are a master! There is probably a cottage industry opportunity for selling carbon fiber deck lids, bonnets, and dare I say doors.
Tom

[GavinT]

 . . . for simplicity sake lotus made this in a two piece mold, but the probably prewet the fiberglass and rolled it up inside that channel with a special roller. Mine had the voids to prove that it was probably done blind like that.

Looking mighty fine, Chuck.
Yeah, Lotus must have used a two piece mould, I reckon.

I've never done an infusion job but agree the 'channels' must have been done blind.
To avoid situations where a resin rich internal corner is likely, I sprinkle a line of chopped fibres right in the corner before the mat goes down.

[Chuck Nukem]

Thanks guys!

I trimmed the top of the mold today. Need to get a friend to help me flip it so it doesn't separate from the mold for side 2. I can't believe how much resin I am using on this damn thing. I have probably burned up 5 gallons already. It's like I'm building a boat or something.

The front splitter popped out of its mold with hardly any prompting...Should be a good sign for the decklid... I have some small repairs to do on the splitter mold, but nothing major. The time to entomb both of them is drawing close.

[BDA]

Congratulations on your splitter! I hope the engine cover works as well!

As I stated before, I aspire to only be stupid about making molds but I wondered if it might make sense to make the bottom edge of the cover from a separate mold and glass it on? It might be just as much work - or even more - but it might be worth considering in case it does make sense. Just a thought...

[Chuck Nukem]

BDA,

There is a strong chance that once I put the flanges on the inside I will not have the access needed to properly do the channel. The plus side is that I can use either mold separately so I should be able to still make it work if I need to bond the pieces together later.

[Chuck Nukem]

First step is complete. The parts popped out of the mold without much fuss at all. It only took about 5 minutes to demold the decklid and the spoiler happened in seconds. Up next is a wet sand and polish before the infusion. Time to dig the vacuum pump out of the attic!

My spray gun had a clog issue when I went to paint (incomplete cleaning...shame on me!) so I decided to brush the rear side on. I probably used 20% more gel coat this way, but it seems to have worked just as well as spraying it incase anyone wants to wander down this rabbit hole.

[Bodzer]

Well done Chuck!

[BDA]

What Bodzer said!

[Chuck Nukem]

Thanks guys!

[Sandyman]

Chuck, with molds like yours you can now corner the market on boots, bonnets and front splitters.

[Chuck Nukem]

Chuck, with molds like yours you can now corner the market on boots, bonnets and front splitters.

Thanks Sandy. We will see what kind of abominations are born from them!

I'm not sure if anyone else is doing this stuff for Europa on our side of the ocean...I know of a few outfits in the UK who have molds, but everything is fiberglass. There was a kid from Italy who posted on here a few years ago trying to drum up interest in a carbon body. I must say it would be cool...

[Sandyman]

Chuck, any thoughts on carbon fiber front and rear bumpers?

[Chuck Nukem]

Chuck, any thoughts on carbon fiber front and rear bumpers?

I got the parts prepped to make molds of and then I decided to just fill the bumper holes on my car for a cleaner look. I may end up making those molds down the road if anyone is interested.

[Chuck Nukem]

She's black!!!

Just base coat for tonight. I had some dust contamination issues so I am letting it dry after 1 coat to wetsand tomorrow for another round of base.

[BDA]

She’s looking good, Chuck! Are you doing A/C? Black is beautiful, but it’s pretty tough in Dallas!