It's been a minute or two since I posted an update - summers are short up here and it's tough to fit in all the various 2 and 4 wheeled activities I want to be doing!
Not to mention trying to maintain some forward momentum on the project and development of parts...
The Carbon Copy has sprouted a strange growth on its roof. A fellow Pelican (thanks, Brookieslayer!) has very generously offered his non-sunroof coupe for mold-making use so I've built a fixture for that. I may even document the process! Hoping to have a mold for a roof skin in a few weeks time.
Can't wait to take a cutting wheel to this... I may have found a home for the sunroof tray (thanks Pelican Classifieds!) so hopefully it can have a second chance at life!
Making a square box fit a round car...
Due to the flange required for the infusion process, the outer dimensions of the mold, for a given part, are quite a bit bigger than the part itself. Which explains the large size of the oven required for curing!
The pattern/mold process generally uses all sorts of tape and gum and shoelaces, glue guns, crafting materials, and whatever works, to make the pattern with which to make the mold. It can be fun, and also frustrating, and either way is incredibly time consuming.
Now for an actual project update... I wanted to start with a 76 chassis. 77 and later had power brakes which added 15 to 20 pounds. By this time in the 911 production the last remaining ungalvanized panel was the roof. A small amount of rust is present on this one but easily rectified, and it's the only rust on the entire bodyshell! It also helps to start with a California car...
Making the mold pattern required removing the front and rear glass, it's also plain to see that the repaint was not really Ice Green Metallic. Close, but it's less green and looks more like a modern paint code from a Japanese Car.
