Fiberglass Bumper Moulds attempt

[andyverran]

Worth a try I suppose, was kinda hoping not to have to go through the whole painful birthing process.

I'll get some pics of making the moulds if that's any use to you chap (when i do the left side)?

[andyverran]

Right...now I have a working gearbox again it's time to get back on with this...

I made the rear bracket as best I could the other day, no chance of doing those right as you can see!

So Tuesday I can drill off the front bracket and make a plasticine mould of it...

[shokenore]

I see you are using the woven cloth, have you used the stranded mat or is there a reason for the woven cloth?
Curious.


And yeah i was underneath the back of my truck today.....
I think the only thing holding the chrome on is the rust.

Molds could make you a fortune

[andyverran]

I used a mixture of different cloth...the brackets were just made from off cuts mind, the bumper outers were different however:

I did the sharp edges and corners (first layer onto the gel coat) in the the really fine tissue like stuff, easy to get in the corners. Once that had gone a little tacky I put CSM over the lot (didn't want the tissue to move as I really struggled with getting the edges right), then the weave over that...partly because I thought it looked better and it wasn't really any more money...might be slightly stronger though that wasn't important since I was making it all as thin as I could.

I did think about making a few if I could do a good enough job of it...currently I'm not good enough...you never know, I may get there one day.

Are you going to bite the bullet on your bumpers?

[shokenore]

I don't know if this is the right method or not but I do mine in a similar fashion as you would with papier mache.

I cut strips off between 1/2 to 2" wide and as long as the piece warrants.
Then paint on the resin and then lay the strips in a criss cross fashion. I have an old paint roller with a rubber wheel the original "paint brush" slid onto.

I use the roller to squeeze down on the fibres and push the resin into the glass.

Once the snorkel is finished the bumpers will probably be next(after the intercooler pipes are done).

Still trying to work out in my head the best and easiest way of doing the bumpers.
I am toying with making the initial form using expanding foam and then skinning the surface in glass...

[andyverran]

That foam stuff is surprisingly effective, have you seen the stuff you mix and poor?

https://www.youtube.com/watch?v=2SW9pp4SxKw

I wondered how practicle it would be to make a giant latex mould of the bumper and fill it with the mix for foam....a layer of 2 of glass and some top coat..

or for that matter to gel coat and glass into latex and then foam fill?

[shokenore]

That was what I was trying to feebly explain.
If it was good enough for Sierra bumpers it will be fine for the back of the truck.

[andyverran]

That was what I was trying to feebly explain.
If it was good enough for Sierra bumpers it will be fine for the back of the truck.

I think that's a damn good idea...I noticed doing the little bit I have done that the glass gets very, very stiff once there's foam in it...

Ply wood box and some silicone do you recon? Should keep a latex mould in shape as it were..

[andyverran]

This working lark does soooo get in the way.

Some small progress today...mud flap on the first side and brackets for the second done...got to mould the bumper quarter as soon as time permits, Tuesday maybe.

Oh and rear tyres with both tread and no punctures, luxury.

[Trunks]

Looking mighty fine there, well done

[RebelV8]

Looking good Andy, should be great when all done

[shokenore]

Thumbs up Andy.

[andyverran]

What a time to run out of foam....won't be getting a mould out of that!

[andyverran]

Had another go today, what with a day off....

Definately going to have to make a frame to contain the foam and part...as it expands it falls away from the bumper since it can't stick due to the mould release wax..so good, in that the wax might work! but bad as it won't hold a shape "free form". The low expansion foam in a can is no good either, just not enough of it and it doesn't expand enough to really get good coverage.

Take 3 next week once the 2 pack foam arrives..

[andyverran]

take 2 failure in pic 1..little pond type frame for take 3...