Have you ever wondered what it takes to make a mold?

[mattw]

Re: Have you ever wondered what it takes to make a mold?

Thanks for the compliments guys..

That does look good , having that much space to do everything makes me jealous Well done Matt

Some questions for you..

1) When I sprayed my gelcoat down in my molds obviously it got all over the flanged edges of the molds.. After I removed the part from the mold I had to clean that gel-coat from the flanges with a paint scraper.. Total PITA.. Is there a better way to do this? I thought about putting painters tape down on the flanges before I sprayed the gelcoat.. Think that would be a better approach?

2) That front cover was a total PITA to remove from the mold. I probably spend 30 minutes getting it loose. If I were to do it again I would probably make it a 2 piece mold and part it right down the center. Is there anything I can do to make releases easier going forward? I've heard you can put air fittings in your mold so that you can use air to help push the part out.. Do you have any experience with that? The really bad areas are right around the fog and turn signal lights.. Its just hard to get down there and get all that released.. Then once you do get it released you have to lift the part straight up(both sides equally) to get it out..

 

[mattw]

Re: Have you ever wondered what it takes to make a mold?

I don't know Matt, I think you are going to have to send those parts to me.... you know, manufacturing has a lot of "waste". lol nice work. I still wish I had the ambition and follow through that you have.

There is a chance the motivation is contagious. Maybe you should come spend a weekend with me laying glass. I promise its a TON of fun!

 

[ziembic]

Re: Have you ever wondered what it takes to make a mold?

There is a chance the motivation is contagious. Maybe you should come spend a weekend with me laying glass. I promise its a TON of fun!

Only a ton of fun? I would think it would be more. I should sneak up (over?) there some Saturday and catch up with you guys. I have motivation on a different project. I am trying to get my Suby back together for Nationals in BG. I have 99% of the parts to get it back on the road, it is just tying up a lot of loose ends and waiting on things to be coated.

 

[92TYPHOON937]

Re: Have you ever wondered what it takes to make a mold?

Looks really good I do need to make it back up there at some point to see ur 4dr

 

[MRKING]

Re: Have you ever wondered what it takes to make a mold?

Thanks for the compliments guys..




Some questions for you..

1) When I sprayed my gelcoat down in my molds obviously it got all over the flanged edges of the molds.. After I removed the part from the mold I had to clean that gel-coat from the flanges with a paint scraper.. Total PITA.. Is there a better way to do this? I thought about putting painters tape down on the flanges before I sprayed the gelcoat.. Think that would be a better approach?

2) That front cover was a total PITA to remove from the mold. I probably spend 30 minutes getting it loose. If I were to do it again I would probably make it a 2 piece mold and part it right down the center. Is there anything I can do to make releases easier going forward? I've heard you can put air fittings in your mold so that you can use air to help push the part out.. Do you have any experience with that? The really bad areas are right around the fog and turn signal lights.. Its just hard to get down there and get all that released.. Then once you do get it released you have to lift the part straight up(both sides equally) to get it out..

Putting tape on the flanges will help with post clean up .It will also prevent bonding of the gel coat/resin if it runs down to the flange edge . I like to use the a/c foil tape from home depot. It's real strong and the temp ratings work well the exothermic cure . Painters tape will work if you already have some .If your not using a ton of hardener and the temps stay low , clear packaging tape does as well .
Removing the part is all dependent on your release and your draft angles on the mold itself . Its almost a 90* rectangle around the fog lights when your lifting the bumper out of the mold . As the mold becomes seasoned from multiple pulls and heat cycles , it will get a little easier . Using more release agent in low draft areas like that will help too .I've incorporated resin feed lines and vacuum lines in some of my molds , so yeah that would be possible to include one for assistance with part ejection . You'd want to cover the hole with some clay or wax to prevent the resin from clogging up the air line though. I have a few plastic wedges with air connections that work well .Slide one or two in between the mold and part , hit the air and sometimes the parts will pop out pretty easily .
You'll learn what each mold likes/dislikes with use . Your definitely on the right track , everythings looking great so far :tup:

 

[mattw]

Re: Have you ever wondered what it takes to make a mold?

So I made some jigs that will allow me to properly align the mounting brackets on the front cover. I am just going to lay this cover up nice and thick and not use a support behind it..

I then CADed up and cut out these metal brackets which will get epoxied to the support then glassed over to hold them in place:

I'm also working on an aluminum version of the front bumper brackets that bolt to the frame:

I glassed up the tabs on my rear corner:

Then did a test fit on the truck:

I'm working on molds for: Rockers, Door Cladding, Mounting Cups, Left Rear Corner, and Mounting hardware.

Its moving along.. Really trying to have my 4-door cladding done for NATs..

 

[canadian]

Re: Have you ever wondered what it takes to make a mold?

Looking great

 

[mattw]

Re: Have you ever wondered what it takes to make a mold?

Looking great

Thanks.. Today the mounting brackets got glassed in place..

Door panel got prepped to mold:

I'm hoping that this week I will be able to install my new front fenders with integrated cladding plus my front bumper cover..

 

[gobabygo]

Re: Have you ever wondered what it takes to make a mold?

Damn !!!! Looking good. You got it figured out. Wish I had the patience to do that. Keep up the good work. Also like the front frame mounts.

 

[mattw]

Re: Have you ever wondered what it takes to make a mold?

I've got my turn signals and fog lights mounted up to my front cover now.. I decided to just go with cheap/generic fog lights rather than trying to find stock sy/ty stuff...

Eventually I'll lay down another layer or 2 of MAT on the back to make it more rigid but first I am going to test fit it on the truck and make sure all is good...

I've also got about 5 more parts ready to mold. Only two rounds of molds left and I should be done...

 

[92TYPHOON937]

Re: Have you ever wondered what it takes to make a mold?

That's all awesomeness

 

[MRKING]

Re: Have you ever wondered what it takes to make a mold?

How is the lateral stiffness on the frame mounts ? You could glass in some gussets if its suspect .

Looks damn good either way :tup:

 

[mattw]

Re: Have you ever wondered what it takes to make a mold?

How is the lateral stiffness on the frame mounts ? You could glass in some gussets if its suspect .

Looks damn good either way :tup:

They actually feel quite rigid. I'll know better once I bolt it to the truck and push it around some.. Thats at least a 16ga steel that I used for the brackets..

 

[MRKING]

Re: Have you ever wondered what it takes to make a mold?

Sorry about that , I totally missed that you inserted steel under the glass

 

[mattw]

Re: Have you ever wondered what it takes to make a mold?

Sorry about that , I totally missed that you inserted steel under the glass

Yeah, I hope thats OK to do.. I sandblasted the metal then cleaned it up really well.. Then I used a 2-part epoxy to glue it to the bumper.. I let that setup overnight then glassed over them with a couple layers of MAT.. They feel really rigid.. I can push on them with all my might(which isn't much) and they don't move or give any indication of coming loose or breaking..

 

[Quickstop [UK]]

Re: Have you ever wondered what it takes to make a mold?

This is a great thread.

How much do you think you could make replacement pieces for? Say rocker panel, rear corner and the front bumper?

I saw $2k for a whole set a while back but I am not even sure those are available. Your moulds as well would be worth quite a bit!

Could you use the moulds you have for carbon fibre? Are there any advantages to CF?

 

[mattw]

Re: Have you ever wondered what it takes to make a mold?

This is a great thread.

How much do you think you could make replacement pieces for? Say rocker panel, rear corner and the front bumper?

I saw $2k for a whole set a while back but I am not even sure those are available. Your moulds as well would be worth quite a bit!

Could you use the moulds you have for carbon fibre? Are there any advantages to CF?

So I've been thinking long and hard about pricing.. I do want to sell some pieces to:
1) Recover some of what I've invested so far in fiberglass tools/materials
2) Buy more parts for my truck

Prepping the original parts and making the molds has taken massive amounts of my time and a fair amount of coin. Actually making the parts in the molds isn't as bad but its still time consuming and obviously the materials aren't cheap.. Before starting all of this I was thinking that I'd be able to sell the parts nice and cheap and make them readily available.. That was before I knew just how much work it really is. I'm now thinking that I'd like to price them a little better than Paul Select but it isn't going to be by much..

My understanding is that my molds could be used to make carbon fiber parts.. Only advantage I see is looks(if you're into that look).. I probably will not attempt it..

 

[MRKING]

Re: Have you ever wondered what it takes to make a mold?

Yeah, I hope thats OK to do.. I sandblasted the metal then cleaned it up really well.. Then I used a 2-part epoxy to glue it to the bumper.. I let that setup overnight then glassed over them with a couple layers of MAT.. They feel really rigid.. I can push on them with all my might(which isn't much) and they don't move or give any indication of coming loose or breaking..

It you start to get delamination , it will become noticeable . You should be ok but if you hit a giant pothole or go all dukes of hazard , give it a check every once and a while .

 

[ziembic]

Re: Have you ever wondered what it takes to make a mold?

It you start to get delamination , it will become noticeable . You should be ok but if you hit a giant pothole or go all dukes of hazard , give it a check every once and a while .

I want to witness the dukes of hazard maneuver. As usual Matt everything looks great.

 

[mattw]

Re: Have you ever wondered what it takes to make a mold?

I'm back at it again...

The mold on the left will reproduce those stupid impossible to find round discs and the brackets that go on the bottom of the doors.

The mold on the right will make and right hand door panel.

I almost have this left hand rocker mold complete:

I've started the left corner mold:

Today I started the left door mold. The only mold I have left to start is the right hand rocker..

This means I am really close to finally being able to make my 4-door cladding.. I'm pretty hyped up and the only thing that is going to get in my way of working on this is a beach vacation in 2 weeks.. Hopefully I can keep the momentum going and get right back into it after vacation..