first timer: sculpt a plug?

General Composites Discussions Composites Talk
#1

Hello, first time on the forums! Kudos to Evan and others contributing!

I want to build my own car parts and my first goal is to build a front bumper. Instead of attaching an existing fiberglassed bumper onto my own, I want to sculpt my existing bumper into shape. I can only think of two things right now: clay and foam blocks/sheets. I will mold this piece and also utilize the mold to infuse or vacuum a CF part… I will also use the same technique for different car parts.

Question is, what kind of clay and foam can I use to sculpt my plug? Must I use duratec primer over it?

thank you for your help!

note: you can see the blocks of foam from the mouth of the bumper.

#2

asdf

foam and some (peach colored) clay?

#3

blocks and sheets of foam to sculpt body of NSX…

#4

bondo and clay on foam.

#5

FG over the foam as the plug.

#6

asdf

#7

did you do the work in the pictures??? :shock:

#8

I doubt it :smiley: There is a website with that ferrari conversion somewhere.

#9

haha knee slapper

of course not… if i was that proficient in composites fabrication, i would be working asap!

well for eye candy… here’s the finished nsx, er… ferrari.

#10

I think I’m going to be sick.

I guess I’ll never know why people would want to pay lots of money to make their car go slower.

#11

Not starting off doing something small eh? :?

#12

small… yeah probably a sideskirt first, but i want to know how the overall technique is laid out first.

#13

Think even smaller for your first time working with fiberglass or composites. Unless you have lots of money to burn…

And then when you understand how to do it, then maybe buy a body kit, redesign it and make your molds from it.

#14

Here is the website with the NSX

http://ahru.co.jp/usercar/index2.htm

I’m building a bumper for my S14 240sx. I’m using the foam block method as well. It works very well. I’m on a budget so I purchase the Green floral blocks that Walmart sells in packs of 6. I use hot glue to glue them together then I rough shape with a knife and cheese grater (body filler grater). Then I sand fine details with 80 grit sand paper and follow with 1-2 plies of cloth and resin. Then I bondo and finish sand to create the plug.

The blocks from walmart are very inexpensive and are very easy to work with. I use the “dry” type.

#15

How big are the blocks originally?

#16

A good size they’re about 8x4x3. Here’s a link:

http://www.joann.com/catalog.jhtml?CATID=83519&PRODID=47821

hmmm… that price on the joann site isn’t too bad compared to walmart. I’m not sure which is cheaper. Same brand though.

#17

floral blocks? i’ve been experienced with floral blocks, but aren’t they a bit too soft and brittle?

GGROP - you’re right! i think i should start something small first and practice with FG.

edit:

i just read up on polystyrene foam and it’s use with epoxy, namely in surfboards. i think i’ll use that along with the floral blocks mentioned above.

http://www.surfersteve.com/polystyrene.htm

#18

Hi guys,

If you never work with fibreglass before, it’s not a good idea to jumps into a big pices like a bumper or a side skirt !!!

I know it because I try to do my front bumper on my civic. It take me abouth 3 years… and it still not finished…

First if you do that, find a second bumper to work on it, I take a bumper from an accidented car ( not too much just a little crac on it that I rip off.)

I draw all the line I wanted on the bumper and remove with a dremel and a saw all the existing bumper I did’nt need,

After that I put some guide with wood panel and carton board, after I spray it with a expendable foam can ( you can find that in any construction store Its for insulation and it expend 3 time of is original space) it take little more than 24 hours to dry and its very easy to work with (cutting and sanding)

THE MOST IMPORTANT THING IS: do NOT PUT FIBERGLASS before your parts is PERFECT !!!

its the biggest mistake I made three years ago and I still pay for that, I was I a rush to see it done and put fiberglass before all the lines was strait and perfect… It easy tu put foam strait Its not the same thing with fiberglass…

I will put more picture of that soon, I have to scan the old pictures (one of the begining, befofe I got a digital cam 2 years ago)

#19

A new project I have in progress

#20

some picture I found on the internet of I guy who make kits cars