need help for my first project

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#1

hey guys,

i’m new to this field and i’ve been wanting to learn how to mould and create parts for my car. for my first project, i decided to make a copy of the fog lamps frame for my corolla (circled in red).

how do i go about making a mould for this? if it’s not too much, could you give me step by step instructions and the tools/materials needed (pictures will be greatly appreciated) for this project? please bear with me as i’m a newbie in these kinds of stuff.

by the way, below are close-up pictures of the frame for your reference.



thanks so much!:slight_smile:

#2

Presumably you are just looking to add the carbon fibre aesthetics to these parts and do not intend to produce this part in high volumes?

If this is the case then I would suggest carbon fibre skinning/wrapping to be your best option.

You simply take the existing part and skin or wrap it in genuine carbon fibre.

#3

Agreed I suggest doing a carbon over lay.

You will need
5 minute multi purpose epoxy adhesive
Small amount of epoxy resin and hardener
A yard of 3k twill
Some china brushes
80,180,320,600,2000 grit sand paper
Clear coat spray paint
Mixing cups

Step one

Cut a square of the fabric and press into the fog light bucket. Get as much as you can in there. Then cut a hole so it will help the fabric form a cone like shape that allows the fabric to be relaxed when it takes te cones shape. Trim some of the excess off but not all of it. Now gently take the fabric off and set it somewhere safe like inside a card board box until later.

Take some 80 grit and scuff the inside of the bucket really good. Clean with warm soapy water and let dry. Mix the five minute epoxy and brush on a thin coat in the bucket. Be sure to get it in the edges as best you can. Gently take the fabric and lay it in place and gently press it into the bucket. Be gentle and work it into place so the weave doesn’t get too distorted. Keep massaging it down and try as best you can to get it to lay over the edges reall nice until the adhesive cures.

Trim as close and you can to the edges of the part.

Mix up some epoxy resin and gently brush it on. Get the fabric nice and wet and let dry. Repeat as necessary until there is a decent amount of resin to allow you to sand it smooth with 180 grit. Brush another coat. Now you will need to begin sanding the extra material down to the edges of the buckets in your case a flat piece of wood and some 80 grit will work then switch to 180 grit as you get close to the edge.

Apply another coat of epoxy and sand smooth with 320 and then hit it with 600. Spray a coat of clear on it and let it dry. Wet sand with 600 and spray again. Sand with 2000 and spray a final coat on.

Very basic instructions here but it will do. Would be a good weekend project for each side if your completely new.

Good luck

#4

Better still, just watch this video.

[ame=“http://www.youtube.com/watch?v=6rTWaV1imzs”]YouTube - ‪How to cover parts in carbon fiber (fibre) by skinning or wrapping‬‏[/ame]

#5

thanks for the responses and video guys. i would like to produce a copy of this part and not just add carbon fiber look to it as this part is rare in my location so i like to keep a spare.

how do i create a plug to create a mold of this? how about the threaded part where bolts/screws are fastened, how are those created as well?

#6

just an update…

i’ve created two-piece mold of the part (front and back) using silicone rubber. i’m planning to put gelcoat and lay fiber mat on the front side. my question is how do i make the back side particularly the part where the screws are mounted? i’ll try to upload pictures of the mold i created.