ed
Member
Registered: 10th Sep 03
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We have fibreglass. 120m of it to be precise.
This is all.
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Tomnova16
Premium Member
Registered: 21st Jan 06
Location: Gerrards Cross Drives: Porsche 911
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i may have a job for you making lotus parts out of fibre glass
http://www.lemass.co.uk/ for all your automotive/bodyshop needs
Located in Chalfont st Peter
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ed
Member
Registered: 10th Sep 03
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That could be arranged. I may have a job for you too
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Tomnova16
Premium Member
Registered: 21st Jan 06
Location: Gerrards Cross Drives: Porsche 911
User status: Offline
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sweet, its bits for an elan (the new gay one) and an esprit
http://www.lemass.co.uk/ for all your automotive/bodyshop needs
Located in Chalfont st Peter
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ed
Member
Registered: 10th Sep 03
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Are they a one off job, or are you looking to make pattern parts for people? I suppose if you're going to the trouble of making a mould then it would be worth making a proper one just in case.
I'm going to try and get the bumpers ready to paint on the 2nd/3rd. Could I drop them off with you to do when you've got some spare time? I also would quite like the roof of the Corsa painting in something glossy so I can take a mould from it just in case I go mental  Would have to do that in the workshop though as there's no point in towing it to your just for that...
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Tomnova16
Premium Member
Registered: 21st Jan 06
Location: Gerrards Cross Drives: Porsche 911
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can do mate yeah
the parts are going to be production ones so not one offs, the guy uses someone in devon at the moment so would be nice to have someone nearer
http://www.lemass.co.uk/ for all your automotive/bodyshop needs
Located in Chalfont st Peter
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ed
Member
Registered: 10th Sep 03
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Ok, I've got a paint question for you too so I'll give you a call later on. Might end up taking some time off and come back down at this rate as I've got a lot of stuff to do back home!
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Tomnova16
Premium Member
Registered: 21st Jan 06
Location: Gerrards Cross Drives: Porsche 911
User status: Offline
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just so you know im away next weekend at a wedding just outside birmingham
http://www.lemass.co.uk/ for all your automotive/bodyshop needs
Located in Chalfont st Peter
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ed
Member
Registered: 10th Sep 03
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Went shopping:
Boring update. It will lead to an interesting update soon...
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ed
Member
Registered: 10th Sep 03
User status: Offline
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Carbon Fibre Roof Attempt Day 1 - Prepare:
I found a half green and half white Corsa:
Got some chemicals - Gel Coat, Resin, Hardners and Paints:
Got a tonne of fibreglass (lightweight CSM, could have done with some heavier stuff but can't complain as it was free):
One of Tomnova16's 
The soon to be obsolete steel roof:
More to come tomorrow...
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Tomnova16
Premium Member
Registered: 21st Jan 06
Location: Gerrards Cross Drives: Porsche 911
User status: Offline
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Ed you got it painted yet?
http://www.lemass.co.uk/ for all your automotive/bodyshop needs
Located in Chalfont st Peter
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ed
Member
Registered: 10th Sep 03
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Yes. But.... I don't think I put enough harder in the paint and it reacted and fucked up. Washed it all off with gunwash and wet sanded the primer down then covered it in paste wax. Should do the job and can compound polish the roof when it comes off the tool.
Bugger.
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Tomnova16
Premium Member
Registered: 21st Jan 06
Location: Gerrards Cross Drives: Porsche 911
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did you sand the roof down before you painted it. As it has a lot of overspray on it
http://www.lemass.co.uk/ for all your automotive/bodyshop needs
Located in Chalfont st Peter
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ed
Member
Registered: 10th Sep 03
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Yep, sanded it all and cleaned it all. 
Had to do it all by hand too because the DA has seized up in the (long) time it's been sitting un-used. I really shouldn't work on cars, I'm not good at it
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a_j_mair
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Registered: 23rd Jan 04
Location: Scotland
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good to see some progress
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ed
Member
Registered: 10th Sep 03
User status: Offline
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Plastered the roof in wax:
I hope to god there's enough on there. I put 8 coats on for good measure. The roll of masking tape kept sliding off it when I was masking up so I think it should do!
Brushable Gel Coat:
Purple, but apparently it's clear...
Gave the roof a nice thick coating of the stuff:
I think sprayable gel coat is better as it was quite tricky to get this stuff even. But you need a gun with something like a 4mm tip on it to get the stuff out as it's too gloopy.
Now sitting here in a state of paranoia hoping I got the ratios right on the catalyst and gel coat after the paint fiasco 
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Leighton
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Registered: 21st Feb 01
Location: Liverpool
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what ratios did you use?
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ed
Member
Registered: 10th Sep 03
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2% catalyst by weight. It's nearly ready for the fibreglass now, just a little too tacky and soft at the moment. As I say, paranoia.
[Edited on 04-05-2010 by ed]
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Tomnova16
Premium Member
Registered: 21st Jan 06
Location: Gerrards Cross Drives: Porsche 911
User status: Offline
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looking good matey
http://www.lemass.co.uk/ for all your automotive/bodyshop needs
Located in Chalfont st Peter
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Jambo
Member
Registered: 8th Sep 01
Location: Maidenhead, Drives: VXR Arctic
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shit the fucking bed, Ed is working on the Corsa
keep it up matey!
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Tomnova16
Premium Member
Registered: 21st Jan 06
Location: Gerrards Cross Drives: Porsche 911
User status: Offline
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Refined Detail and Lemass will be over later to check everything is up to scratch 
http://www.lemass.co.uk/ for all your automotive/bodyshop needs
Located in Chalfont st Peter
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ed
Member
Registered: 10th Sep 03
User status: Offline
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Ok, I'll admit that the mould should have been a two piecer because it needs to go in the back of my car, but lets ignore that minor detail right now. I'll just drive back to Brum with it hanging out the boot of my car
Here's the resin, not expensive but takes a fair bit of work to wet out the fabric. I found the best technique was to use a roller to get the most even coat using the minimal amount of resin.
No progress work as once you start you don't stop! I was going to let each ply dry a bit first before applying the next, however I made a quick phone call and found out that this stuff doesn't get overly hot if you do it all at once. So no progress pics, just the finished mould waiting to get pulled later on today!
I hope there are no voids in there because ideally I don't want to have to do any bodywork on the mould as that would result in it needing to get painted. The trickiest part was getting the fabric to go down into the gutters and stay there!
We will see!
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3CorsaMeal
Member
Registered: 11th Apr 02
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do you need to add wood or anything like that?
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ed
Member
Registered: 10th Sep 03
User status: Offline
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Maybe. It's good to have a tiny bit of flex in the mould though. Also, I looked and the chassis moulds that were made with this fibreglass and resin combo before and they achieved a stiff enough mould without reinforcement.
[Edited on 04-05-2010 by ed]
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ed
Member
Registered: 10th Sep 03
User status: Offline
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The reason I haven't added and reinforcements right now just for good measure is that if the mould decides to give me grief when I try to pull it, it would make things a good deal harder to get it off!
Once it's off, it can go back on again for wood to be added if required...
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