How to make custom bumperettes

[SLOSpider]

What about some kind of mold release instead of just wax?

http://mclube.com/mold_release/composit ... ld_release

[azygoustoyou]

Yeah, I was thinking just the same. I should get some PVA or something. Then I could hopefully get a few bumpers out of it. I'll try to get some either today or tomorrow so I try to finish the first bumper this weekend.

[azygoustoyou]

On my search today to get some PVA. I was able to talk to a boat maker. He told me how to go about putting the fiber cloth and resin in the mold. I purchased at his store some 100% carnauba wax to release the bumper out of the mold. I also bought an acetone to clean the brushes. Lacquer thinner didn't work.
He told me to wax the mold, wait 30 min. then wipe it off. Wait 30 min before you wax it again. You want to wax it 10 times. He also said that you don't want the layers of fiberglass to completely harden. Or you should scuff it up so the next layer will bite. When using the fiber cloth, you should use different cloths. Use the thin material to start out with a couple layers, then use the thick matte cloth. Do this back and forth until you get your desired thickness.
I told him about the spot glaze putty. He said it was fine. All I would need to do is wax it once it's sanded. There is no need to paint the mold.I'll try to get the waxing completed tonight and start the bumper in the mold tomorrow.

[azygoustoyou]

Bumper mold is sanded and I'm starting the wax.

[So Cal Mark]

I'm impressed you've stuck with it this long.

[azygoustoyou]

I know. This is crazy. Determination

[So Cal Mark]

I'll start referring potential customers to this thread when they ask why my fiberglass replacement center consoles cost $175!

[azygoustoyou]

I would think if anyone would want bumperettes. They would have to realize the extend of what you have to go through to make them after this. Who knows maybe I'll get faster but the steps are crazy. So far I have about $110 into this project.
I still have some material left.
Resin x3= $36
Fiber cloth Matte = $5
Fiber cloth x3= $15
Brushes x25= $25
Carnauba wax = $22
Acetone =$10
plastic cup =$3
Not accounting for tax. "OR my time" I'll update the cost as I need more material.

[Foster48x]

Remember this thread?
http://www.fiatspider.com/f08/viewtopic ... umperettes. Now we know why.

So, at this point if you had to sell them for a living what do you think you'd have to charge to make it worth you while?

Rick

[azygoustoyou]

I don't know if I'd want to make them. Maybe if I just made the shell and you connected to your car. $200
I could show how to do that. But you have to think though. It would cost about $25 in material just to make one. So is that really worth it?

[azygoustoyou]

I got tired of waxing. So I only put on 8 coats. I got the first bumperette in the mold. I'll wait till tomorrow to pull it out. I used about 10-13 cloth/matte thick. The cloth is easier to work with but isn't stronger than the matte. I put on the cloth first then alternated with the matte. The matte is messier and wants to stick to you but is nice because it's thicker. I mixed 2 oz. of resin at a time. I would suggest to mix at least 3 oz. I put the acetone in a cup. I figured I'd clean the brushes as I'm mixing more resin. I go to pull the brushes out of the acetone and what do you know. They're hard as can be. So the acetone was a waste of money. Don't figure on reusing the brushes. I wasted about five brushes because of this.
Have a lot of cloth ready. It goes into the mold a lot faster than making the mold. It gets pretty hot also. I mixed 10-11 drops of hardener instead of 12 per oz. It still hardened pretty quickly. If you have the capability to do this in a cool area. It would save you some money. I'll support the inside later to put the insert nuts in so I can bolt the bumper onto the car. You could also make it to connect to a pipe with a "L" bracket on the end that would fit into your bumper hole.

[azygoustoyou]

i decided to try to pop the bumper out of the mold tonight. I gave me hell and cut my finger. Don't waste your time. Use a PVA. It wasn't worth using the carnauba wax. Or maybe I should have waxed the other two times. I'll let you know when I do the next bumperette. I was able to get it out. I did damage the mold some though. I think it's salvageable. The bumper looks good. If it's this hard just getting them out. I definitely won't be selling them. Now all I have to do is make three more.

[Danno]

I think you should have just covered the wood and called it done. this is getting to be quite a process. I remember back in my Aerio days we talked about making CAIs by carving the shape out of fairly high density Styrofoam, then you wrap it with fiberglass and you could then dissolve the foam out of the middle leaving the shell. I wonder if that is a process that could be adapted to this kind of an application. at any rate, I know whatever you do will still turn out to be wicked cool and just ads to the uniqueness of your car.

[SLOSpider]

I think one more problem and he will just make them all out of glass covered wood....

[azygoustoyou]

That would be cool if it was possible to do it like that. It sure would be a lot quicker that this method. There's no way I'm stopping. I'm making this set for my car. I would think I would be able to get at least one more set after mine. I think the mold will crack more after the next one ruining the mold. I think it's worth making a one of a kind bumper. If I could get a better release. Then the molds could be salvaged.