Anyone ever made their own f/g panels (eg. speedster clamshell)

[obrut]

Hey all,

I'm having zero luck finding a speedster clamshell for my early speedster project (for less than silly $$$'s).

Anyone ever made a f/g panel like this? I would appreciate your thoughts on how to, how hard, useful books or links etc

What about shaping up something like a surfboard blank and then glassing it?

[Paulporsche]

Depending on the size of the piece, you might try carving a buck out of styrofoam and then covering it with plaster which you can further smooth to a hard surface. For something larger, a wood armature covered with wire screen can then be finished off with a layer of plaster.

Perhaps a search of the internet will yield info on types of fiberglass, parting agents, gelcoats etc.

Good luck, and please post your results.

[Fishcop]

Ryan, I'm sure I've seen some replica clamshells on the 'net before... have you done some surfing? Another thought would be to track down a real one and bribe the owner to allow you to have a mould made.

[Dave Nordhoff]

You will need to make a male plug and a female lay up mold (fiberglass) from your plug and then laminate your part in lay up mold. It is a big project and starting with a perfect plug is the key. I work in aerospace composites and I hate to discourage you but with my experience I would buy one. The cost of materials can add up quickly (gel coat, resin, fiberglass, foam, mold release, gloves, cups, bondo, lots of acetone, ect.) and its a sticky, itchey and smelly process.
I recently made a carbon fiber CIS air box cover and I must 80+ hours into it and thats working in a well equipped shop.
Good luck and keep us updated.

[Zeke]

I have designed and made many parts. You need a female mold of good quality so the work necessary to paint the part is held to a minimun.

To make a female mold, you need a male plug which can be made by either method mentioned above. It is a long and expensive pocess. Even the right kind of plaster isn't cheap.

My advice is keep looking. If you must make the mold. come back or PM me and I'll see what I can find for you to read. The one advantage is that you could make the part for others to defray expense.

Don't quit your regular job. I got out of the FG business many, many years ago for a reason. You will discover that reason if you go whole hog into this.

[obrut]

Thanks guys - I thought it would be a pretty tough job - I'll keep looking