BHP_Alex

Hey fella nah dont worry no scoop on the roof lol rad is rear mounted though, that car is a honda VTEC rear engined rwd.

Yeah got the wire now lol

Cheers

Page 8 woohoo

BLU

iTrader: (27)

BHP_Alex

Hey All

I have an update for you i have started a couple of projects on the go to see what happens first one is the rear arch shaping so i can get it how i want it so here is some pics of how i am doing it first you have to make the disired shape then take your fibreglass mould from that

So i started off by tacking the old quarter panel back onto the car in the correct place to use for shapeing then covered the wheel and inner arch in plastic sheeting seen here :



you can also see where i have built up with cans and boxes so the foam wont drop all over the place



then once you have done this it is a case of applying the foam i used a whole can anyway lol which left this:
I recomend using latex gloves with all this work as the stuff is a knightmare to get off your hands lol



then after a hour or so it looked more like this



you can also see where i took the grinder with a wire wheel to the panel just to rough it up so the foam / filler will stick to it

while the foam was going off, i found a standard rear mini ligh unit and thought how i could change it so i stripped it down and set it up to take a mould from it to see if i could then i plan to modify the mould to how i need the inside of the lense to be to try and build up a custom led board to fit to try and give the rear lights a modern feel,

So to build the mould
- First i made up a box a little bit bigger than the light unit then half filled with damp sand and placed the light in,
- Then i shaped the sand around the light to create the mould seen here



- i then cleaned off any sand from the light itself
- Then i watered down some PVA and brushed this all over the light unit if this was a good idea i am yet to find out lol, the idea was that it would give a break between the mould and the light, you can see the PVA in the picture above aswell,
- I then found some old plaster board bonding paste in powder form so i mixed that up to quite a wet mix then poured into the mould to fill it completely to the top of the box for strengh as seen below



Then poured into the mould



so we shall see what i come back too tomorrow night will probanly have to add some more expanding foam to the arch i would have said as i need a lot there to form the shape

Thats all for now

StuS

iTrader: (5)

Double post - delayed by 12 minutes?

Look forward to seeing what the plaster board paste does tomorrow!

MAGNUM Type R

iTrader: (6)

This project is MAD keep up the good work

BHP_Alex

Hey all first off the foam had'nt expanded as much as i though it would have so added some more onto it to get the build up that i need seen below



This wasnt looking like enough foam to trim back so waited for it to expand a bit to see what happened

So i had a look at the mold to see what had happened there so first off lifted the mold up and turned it over to see what i was left with



- I then rinsed out the remaining sand from the mold and attepted the part removal, thats where the fun began lol manage to remove it but where the part had too many angles was bit akward so ended up with this





- In the next pictures you can see that it should work well with the final design just need to spend a bit more time making the mould a lot neater really





but the theory is good just needs some tweaking,

After i had done that the foam hadnt expanded very much so got a differant version out the shed to try that and it applied loads better so recomend the yellow not the red stuff and here is what i was left with so you can see on friday i will be able to start trimming down to get the shape of the arches somewhere near ready for filler

- I also wasnt happy with the foam not coming out past the wheel so created a lip around the wheel rim so that i could get the foam to sit there rather than dripping onto the floor lol so result is loads of foam

this pic shows the extra lip fpr the foam



then more foam the last i hope lol





cheers for the comments guys

Mikey Ace

iTrader: (1)

what a bonker, fun and exciting project this is....

I can't wait for each and every update - great stuff

BLU

iTrader: (27)

You're nuttier than a bag of hazelnuts

Good thinking, hope it works
You can get blocks of stying foam to shape for mould making. HTA or ABW might know where to get it!
Your enthusiasm has got me researching a similar project (not a mini) as it looks like fun

V4JDMSTi

iTrader: (2)

If it was me I'd get some thin mdf that has been scored on the back and bend this to the desired shape. Then build a frame to support a top layer. Then make adjustments with foam / filler. It will be stronger to make a mold from. Probably cheaper too. Keep up the good work though

BHP_Alex

Hey guys cheers for the comments price is free for cans as my dad is a builder lol doing property development so gets a few, the red stuff is fire proof which you have to use now for building regs in certain areas and with the new preassure testing of houses aswell as thermal heat loss checks it gone mad, yeah next one o will make up some thing to sit over the wheel a bit to use less foam but this stuff is well strong lol sticks to everything, start shaping tomoz and see what i end up with,,

Blu-Scoob pm me your thoughts and if you need any measurements i have looked at several differant ideas now lol everytime i see a old car i look at it and think lol

scoobyc

iTrader: (2)

awesome.

n8i

iTrader: (3)

hi there

looks really interesting with the 2 kinds of foams
I would have taken some fence and on both sides fibre glass mats, formed in the way you want it. Or wouldn't that be a solution to make models adn ... ?
Good luck with that great project!

cheers
Nico

BHP_Alex

Hey fella not fully sure what you mean, could you explain a bit more i need all help i can get as this is on first time i have done this so is all new to me

Cheers

pot1175

iTrader: (14)

As sugested earlier, try p.u board which can be shaped, then take a fibre glass mould off this. Hope it helps.
i use this all the tme to make one ff grp bits.
http://www.ecfibreglasssupplies.co.u...4ft-x-4ft.aspx
Great work so far btw.

GJUK

Wow, what a fun project you get here, I will be keeping an eye on this now..keep up the great work....

BHP_Alex

Hey All heres this afternoons antics let me know your thoughts then

- First shaped foam somewhere near to how i wanted it







- Then i got out the good old trusted plaster board compound lol mixed it up and stuck a layer on to bring it up a bit nearer to the sahpe i needed like so







- then when that was dry i ground down the seam as on the new shell that wont be there so not needed

- I then got some proper filler on did a couple of layers and left it to dry properly so in the morning i can get sanding check for shape and some more filler till it looks spot on then go fro there









All thoughts welcome, also need some tips on how to get the other side to match lol

Cheers for all the great comments guys

V4JDMSTi

iTrader: (2)

Coming along make a cardboard prfile so you can get the other side the same.

zakscooby1

iTrader: (8)

awesome fella,i check every night to see if progress is being made and your not 2 far good luck

niktiler

iTrader: (5)

excellent taking shape nicely Got to admit had my doubts when i saw all the foam

Dazzles Fiesti

iTrader: (2)

Hi all, just sat down and went through this whole thread!
Reason being, my friend Mogsmex told me about it. I'm the guy he mentioned way back in June who's building a MK1 Fiesta with full Subaru running gear.
I'm going to start a thread on it to show you what we've already done.

Alex, good job you're doing there, keep up the good work

BHP_Alex

Hey all heres todays progress more filler and more sanding and more filler







Cheers again

And to fiesta bloke cant wait to see your thread

oadamo

iTrader: (1)

is that the set ride hight, the first time you hit a pot hole its gonna smash it right off lol.
adam

BHP_Alex

Roughly the set ride height but also the other wheels i have got are slightly more inset and slightly narrower tyres so i have allowed for this

cheers for the thought though

WRX_SWRT

iTrader: (2)

still amazing keep going dude

wrx287

iTrader: (8)

Great going mate. Going to keep an eye on this.
I had a similar idea last year. After seeing the work it's involving im glad i didnt

bengreen85

i think you should keep those wheels on or mayb put subaru speedliners on if they would fit. The car wont handle as well with thinner tyres with a narrower inset. if u put a smaller circumference wheel/tyre on compared to the 16" subaru 1s then they might just spin up especially in the wet?

ps- arches look WIKED!!! just need to hollow the inside out and then make another 3 that are symetrical lol

BHP_Alex

no hollowing to be done as these are just the plugs, which i will be making fibreglass moulds from to create the final fibreglass panels from, the wheels i am going for are 16 inch compomotive mo-5's and it is only the tread tyre width that will be narrower slightly

cheers for the great comments guys

Neil..

iTrader: (35)

Luvin that arch.

Hope the other three turn out the same.

scoobyc

iTrader: (2)

awesome stuff. Lovin the arches

Olly.Wrx

iTrader: (10)

The arches are looking very good,nice work keep it up.