This is becoming the positive mold for the bonnet and dashboard.
The finished positive mold is made of plywood with a shaved layer of polystyreen foam. The foam is made smooth with a layer of epoxy that can be sanded. The epoxy is topped with wax to be sure the product will lose from the mold.
On the wax I put two layers of glassfibre with epoxy resin. To be sure all air will be removed I put a plastic bag around the mold, pumped by an old vacuum cleaner. On top of this layer I form the klegecell layer of 6 mm with the help of an hot air gun (paint stripper). This layer gets glued on the glassfibre layer with some thickened resin in the vacuum bag. After this the foam can be sanded to a nice smooth surface. The holes for the backlights are made from a piece of PVC rain pipe.
On this surface the outer two layers of glassfibre get laminated. The boot lid is sawed out afterwards to be sure to get a smooth connection.
At this moment I choose to make a hardtop (basically because of the weather condition in the Netherlands). The mold is made of plyewood with a toplayer of glassfibre. The front window is bought at Donkervoort because of the beautyful curved shape. I made the front window frame by shaping a sandwich of aluminium klegecell aluminium on the front window.
If you want to know more about me or my car, or have any suggestions or good links please contact me;
© 1999 [email protected]
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