Hey guys, I am starting to make a mould for this seat cowl for my motorcycle. The mould will be pretty straight forward, but I am unsure of how I can replicate these mounting tabs. It uses self tapping screws into the plastic pegs. I could either fill the indents with clay and mould one solid shape and figure out the mounting pegs once I have a finished carbon fiber part, or I could mould the existing part exactly as is to be able to mount some pegs to later on. Does anyone have experience doing something similar to this?
I have a couple different ideas. If I mould the part exactly as is I could find some threaded pegs or a small diameter plastic rod that is drilled out that I could bond to the indents of the part (Picture #3).
As for the pegs that have no mounting platforms, I was thinking I could do a small 1" x 1" wet layup of carbon fiber or fiberglass on the back side of the part to replicate the angle that they need to be mounted at. Then bond on some pegs to the wet layup and release them from the original part. I could drill small holes all around the 1" by 1" mounting platform to create a mechanical lock when I join the two parts. This seems like the best route for the other two pegs (picture #4) although I am unsure how I could replicate the mounting angle for the wet layup without having to remove the pegs on the existing part (I would like to keep this part in usable condition).
Before I get started making this mould do you guys have any other ideas or recommendations? Am I making this harder than it needs to be? Thanks ahead of time!
