Fibre Glass

[Ntrprise]

This was in the technology forum but I thought it might get more views here. Any help would be so much appreciated: -

I have designed and am building a 750 Formula Car with a friend. The chassis is pretty much complete. I now am starting on the fibreglass body.

I've just purchased 50kg of 2 part expanding foam. However, I am not sure of the best way to use it. I guess I have 2 options:

1: Build a wooden rectangular box, which the whole car could fit into. Then put more wood boxes in the inside to represent engine and chassis etc (to save on amount of foam required). Then put loads of foam in there and then sand back to the shape I require.
= 1 full size model of the car I can then fibreglass over.

2: Do the fibreglass in sections. I think I will have the total body consisting of 5 sections of Fibreglass; (front left, front middle, front right, middle and back). But then I worry about the sections fitting snugly together.

Anyone got any advice? I am based in Staines just in case anyone wants to earn a few beers or a curry and visiting us to give some proper advice!!! (Is there no end to my generosity)?

[james_williams]

Only done one mould for a complete car before and this was the method I used. It seemed to work.

1. Sketch out the shape of the car from a side, front and rear elevation. If you can use CAD this will help.

2. Get a large wooden base that the car would fit into an rout slots cross ways (transversley to the direction of travel of the car) at set intervals say 200mm.

3. Create a spine for the shape of the car by cutting chip board to the shape at each interval and screw each 'vertebra' into the base.

4. Once you have the spine fill the gaps with expandable foam and sand back to shape.

5. Sand, Fibreglass and fill as desired. Then seal the whole buck in 2 pack paint and polish.

6. You than have a full size 'buck' for the car which you can take moulds off.

I found this method good as it allowed you to see the whole car and change its shape as you saw fit. Infact, the shape of the car was developed as it was made. It is time consuming and messy and you will need some power sanders.

Good luck.