22 replies to this topic

[Rogue Se7ens]

that was a very good answer though just to clarify, if i was to make a peice of mdf shaped like the normal dash rail, and bolt it to where the dash rail goes, then foam and fibreglass over it would that work? or would i have to put some material over the foam and cover it in resin, then matting? thanks for your help

I would use a thin flat piece of mdg and cut the profile of the dash rail you want. So lay it out on the floor, get the width it needs to be from your Mini, and then sketch out the shape of the top and bottom profiles (similar to the e type). You could then add a couple brackets to it for mounting in the car and test fit it. You could also glue on the foam and even sand it while in the car, but sanding the foam will make a mess. Anyway I would take it in and out of the car, making any adjustments in shape and fit needed, and then apply a thin coat of resin with it out of the car. You can then build up a few layers of material, trying to keep if even and as smooth as possible. Once you get the shape and material thickness, you will be spending time sanding it smooth and adding a couple skim coats of bondo to achieve a good enough finish to paint.

Keep the questions coming, it's a long process, but I'm sure you'll get it.

[Down&Out]

by material do you just mean a process like paper mache? i.e - putting stips of mateial over the foam then painting resin over it or do you mean painiting fg matting ver the top. (sorry i may be a bit stupid )

[Rogue Se7ens]

Yes by material I was referring to the glass. Personally for something like this I would rather use woven glass fabric, something light weight like 6 to 10oz, it conforms easier to the curves you will no doubt have. If you do go with mat, I would lay the mat over the flatter areas first (like the top of the dash). Lay down a little resin then lay on the mat (have it cut to shape first) and then wet it out. I wouldn't wrap around the tighter curves (like the edge facing the driver) yet. Let it set up and then do another layer just cut the mat a little smaller so that is steps up to the next layer, and let it set up. Oh, if you have a small roller that will help in getting air bubbles out, otherwise you will need to do a lot of stippling (poking at the surface with the end of your paint brush). Once you have the larger surfaces done you will be ready to do the tight curves. Here I recommend tearing small pieces of your mat (like paper mache) and sticking them to the curves with resin and your brush. Keep these layer very thin, even if you have to try to peal the mat into half the thickness, this will make it much easier to do the curves. Continue building up the curves and blend the mat over the other hardened areas and you will soon have the whole part glassed.

Please post some pics as you go along, like your basic shape, with the foam attached and after it is all shaped and ready for glass.

[Ethel]

Rogue's given some good pointers there. If it's a one off it would be a waste of time producing a mould. You can also get PU foam in aerosols a bit like shaving foam.

Getting glass matting to conform to tight/complex corners is a pig, polythene sheeting and cling film are handy for holding it in shape.

[Rogue Se7ens]

Getting glass matting to conform to tight/complex corners is a pig, polythene sheeting and cling film are handy for holding it in shape.

That is a good point, not only can it help keep the mat in place, but it helps keep your hands out of the resin. You could even go a step further and vacuum bag it. I've even heard of some without the equipment sticking the part in a large bag and using a shop vac to suck the air out. If you try this you would need to either leave the vac on until it set up or seal it well enough so that it will hold the vacuum.

[Down&Out]

thanks for all this info i will post pics but it may be a while yet rust has to go first

[Tomf]

I think you have seen the start to the guie in my project already, i think ill be doing some more to iv very soon, to complete the guide.

[Down&Out]

yeah iv seen that im glad your doing that it will be useful for me. good to hear your doing some more soon