Fiberglass

[hypercarfanatic]

Hey Everyone!
Has anyone made any fiberglass parts? I am looking around for different cosmetic mods, but I cannot find them the exact way that I want them, so I figured I would try my hand at making them.

Specifically, I want this hood
http://www.carid.com/scion-fr-s-custom-hoods/
in OEM Raven/Black. I do not want to buy it in CF if all I am going to do it paint over it, and I figured that fiberglass would be fine.

[boredom.is.me]

Just modify the OEM hood. If you are considering making FG parts, then modding would be no sweat.

[hypercarfanatic]

Originally Posted by boredom.is.me

Just modify the OEM hood. If you are considering making FG parts, then modding would be no sweat.

I am at a loss of how to modify the hood to replicate this hood. Can you provide any insight?

[hypercarfanatic]

So boredom, from what I understand after some googling is that you are suggesting adding a hood scoop/vents to the OEM hood. However, how would you suggest attaching these two? From what I read, it will ALWAYS fail because of the different materials. I don't like the looks of rivets/screws, and am hesitant to use fiberglass to attach it, because I would not be able to revert the hood to its original state.

[boredom.is.me]

Did you plan on making an entire hood from scratch? If so, then I didn't think modifying would have been an issue. I didn't say to mod the only good you have. In sure an OEM hood won't break the bank. Unpainted or any color wouldn't matter since you would have to paint it anyway.

I can think of plenty of ways to replicate that hood. Use your imagination. I'm not trying to come off as a prick, but you wrote/spoke like this is an everyday thing. You might be in over your head if you can't make an add on.

[wheelhaus]

Which hood were you referring to? The link doesn't seem to work correctly.

I agree with Boredom, especially if you've never worked with composites before. From your questions it seems like your expectations are quite optimistic. Making something as large and cosmetically perfect as a hood with a modified shape from the original, is quite an endeavor. I work with composites every day and it's not something I'd recommend to anyone unless you're REALLY dedicated to it. It will also be a bonded assembly. The skin is only the first part, you'll also need a backing structure or a core material to add rigidity. Then there's the hardware and hinges, which need to be aligned near perfect, and bonded. It's not something we could give you a few tips and you could run with it. It's going to be a lot more work than you're expecting. If you're really dedicated, I could offer some advice, but I just don't want to see something snowball into weeks and months of wasted time for a result you're not happy with.

I believe the best end result would be to purchase the carbon hood and paint it. It will be lighter and far better quality than making it yourself from glass. With any typical composite, left unchecked, the resin will turn yellow and brittle over time from sun exposure anyways. You could also paint it black but mask off a thin carbon stripe, and UV clearcoat the entire thing, so you still get the black you're after, but with a really slick subtle touch of visible carbon.

You could also contact the company and ask them if they could manufacture a special order made from fiberglass. It's the same process, just different fabric. If it could knock $100-200 off the price, might be worth it.

[hypercarfanatic]

Thanks to everyone for your response. You are all correct in your assumption that I have no experience working with fiberglass. However, it is something I am willing to dedicate time and effort to in order to learn, because it seems like a worthwhile skill to know. I will search around and find something that should be a little more simple.

As for this project, I will check my options and see what is the most cost effective. I like the idea of getting the custom order, but I thought it would be more expensive (significantly). I will however, call and ask.

[hypercarfanatic]

Originally Posted by boredom.is.me

Did you plan on making an entire hood from scratch? If so, then I didn't think modifying would have been an issue. I didn't say to mod the only good you have. In sure an OEM hood won't break the bank. Unpainted or any color wouldn't matter since you would have to paint it anyway.

I can think of plenty of ways to replicate that hood. Use your imagination. I'm not trying to come off as a prick, but you wrote/spoke like this is an everyday thing. You might be in over your head if you can't make an add on.

You don't come off as a prick at all. You're simply giving me the information that I wanted. I have next to no knowledge about fiberglass, and its a good thing that I did not try and undertake this project.

Anyways - what I meant when adding a hood scoop: the website says that the scoop requires "molding" to the hood. However, (with a little googling) I think that trying to fiberglass a aluminum hood and fiberglass scoop wouldn't work. The only readily available hoods thats I can find are are CF, so the cost of paint + new hood + scoop is more than the already built hood and paint. I will however, do some more searching.

Thanks!

[wheelhaus]

Originally Posted by hypercarfanatic

Thanks to everyone for your response. You are all correct in your assumption that I have no experience working with fiberglass. However, it is something I am willing to dedicate time and effort to in order to learn, because it seems like a worthwhile skill to know. I will search around and find something that should be a little more simple.

As for this project, I will check my options and see what is the most cost effective. I like the idea of getting the custom order, but I thought it would be more expensive (significantly). I will however, call and ask.

That's a good approach, start small. You can find tutorials and how to's for all kinds of projects with composite materials, but getting them to turn out high quality is where it gets difficult, because you're turning fabric and goop into beautiful shapes. Experience, experience, experience. Pay attention and study how you do things and how they turn out, and constantly work toward making a better product. Composites is a very labor intensive craft. If you enjoy it, it could be a lot of fun.

[Shankenstein]

Originally Posted by hypercarfanatic

Thanks to everyone for your response. You are all correct in your assumption that I have no experience working with fiberglass. However, it is something I am willing to dedicate time and effort to in order to learn, because it seems like a worthwhile skill to know. I will search around and find something that should be a little more simple.

As for this project, I will check my options and see what is the most cost effective. I like the idea of getting the custom order, but I thought it would be more expensive (significantly). I will however, call and ask.

Howdy HypercarFanatic!

I've built a couple fiberglass hoods, but they're usually just quick-and-dirty parts to cover the engine bay. To do it properly, you'll want to follow procedures like this:
[ame]http://youtu.be/UgKvDw1E60E[/ame]


These guys didn't cut any corners. Here's the basic procedure:
- Clean the part
- Build in draft angles (for mold release) and cover holes
- Create flanges for upper and lower molds
- Wax the surface and apply PVA
- (optional) Spray out some gel coat as a first layer
- Lay up fiberglass to reinforce the mold until you're 2-3x the part thickness
- Remove the flanges and flip the part
- (optional) Spray out some gel coat as a first layer
- Lay up fiberglass to reinforce the mold until you're 2-3x the part thickness
- Allow to cure and separate the mold along the parting line
- Clean the mold and polish if necessary

For a fiberglass hood, you don't have to perform vacuum bagging or infusion, so just lay up a few layers on each side of the mold. Cut the edges and adhere the two halves.

For a vacuum infusion, set your ring of bagging tape, lay your carbon/core pieces, peelply, mesh, spiral feeder, inlet/outlet ports, and bag (don't forget to pleat). Draw a vacuum and test the seal. Open the resin line and let it infuse. Let it vacuum off the excess and clamp the lines. Cure, remove from mold, and attach the two sides.

For vacuum bagging, just start a wet layup in the mold directly. Leave room for the ring of bagging tape. Lay your peelply, mesh, outlet port, and bag. Draw a vacuum and test the seal. Vacuum off the excess resin until the vacuum pump stalls. Cure, remove from mold, attach the two sides.

It's alot of fun, and you'll learn a useful skill... if you have the time/motivation/space.

[hypercarfanatic]

Originally Posted by Shankenstein

Howdy HypercarFanatic!

I've built a couple fiberglass hoods, but they're usually just quick-and-dirty parts to cover the engine bay. To do it properly, you'll want to follow procedures like this:

These guys didn't cut any corners. Here's the basic procedure:
- Clean the part
- Build in draft angles (for mold release) and cover holes
- Create flanges for upper and lower molds
- Wax the surface and apply PVA
- (optional) Spray out some gel coat as a first layer
- Lay up fiberglass to reinforce the mold until you're 2-3x the part thickness
- Remove the flanges and flip the part
- (optional) Spray out some gel coat as a first layer
- Lay up fiberglass to reinforce the mold until you're 2-3x the part thickness
- Allow to cure and separate the mold along the parting line
- Clean the mold and polish if necessary

For a fiberglass hood, you don't have to perform vacuum bagging or infusion, so just lay up a few layers on each side of the mold. Cut the edges and adhere the two halves.

For a vacuum infusion, set your ring of bagging tape, lay your carbon/core pieces, peelply, mesh, spiral feeder, inlet/outlet ports, and bag (don't forget to pleat). Draw a vacuum and test the seal. Open the resin line and let it infuse. Let it vacuum off the excess and clamp the lines. Cure, remove from mold, and attach the two sides.

For vacuum bagging, just start a wet layup in the mold directly. Leave room for the ring of bagging tape. Lay your peelply, mesh, outlet port, and bag. Draw a vacuum and test the seal. Vacuum off the excess resin until the vacuum pump stalls. Cure, remove from mold, attach the two sides.

It's alot of fun, and you'll learn a useful skill... if you have the time/motivation/space.

That is awesome! I can't wait to do it. I have worked out a deal with a local fiberglass shop - I will come in and clean up after hours in exchange for for lessons in how to work with the stuff, so hopefully I will be able to do this relatively soon. Now the question is - what do I make first :P?

[wheelhaus]

Lol that video makes it look so easy...

[wheelhaus]

Originally Posted by hypercarfanatic

That is awesome! I can't wait to do it. I have worked out a deal with a local fiberglass shop - I will come in and clean up after hours in exchange for for lessons in how to work with the stuff, so hopefully I will be able to do this relatively soon. Now the question is - what do I make first :P?

THAT is awesome. What kind of stuff do they specialize? Composite shops cover a HUGE range of industries, from quick and dirty methods used in the marine industry, to high end aerospace where the "shop" feels more like a lab, so two shops may have vastly different MOs. I've also seen a lot of bad habits and really poor workmanship in nearly every area... Hopefully they run a good shop with people who know how to do things right.

Feel free to throw questions at us if you like!

[hypercarfanatic]

Originally Posted by wheelhaus

THAT is awesome. What kind of stuff do they specialize? Composite shops cover a HUGE range of industries, from quick and dirty methods used in the marine industry, to high end aerospace where the "shop" feels more like a lab, so two shops may have vastly different MOs. I've also seen a lot of bad habits and really poor workmanship in nearly every area... Hopefully they run a good shop with people who know how to do things right.

Feel free to throw questions at us if you like!

It is I am SO happy they are letting me. It is a bodywork/tuning shop/rice rocket creation place :P. They are not soly a fiberglass shop, but a good portion of there workspace is dedicated to it, and they have all the equipment. I know they put out good work - my parents have gone their for years, and a couple of professional mechanics I know personally always refer people, so I am assuming the quality is good.

Oh, and yes! I will be back with many a question, I am sure :P