Making Moulds

I'm a composite materials graduate. I have been involved in the design and manufacture of numerous moulds over the year manufacturing small craft moulds etc. The cheapest materials are standard e-glass with polyester resin. Its the chap you make most million pound yachts out of.

Firstly you need some male plugs. Foam and wood is the best, as its cheap, easily available (i.e. from building sites), very easy to shape etc.

Once you have made you plugs, you need to seal you moulds with a sealant. I would use wax compared to chemical release agents on a home made mould. Then you need apply a gel coat, then tissue, followed by 4 to 6 layers of CSM.

As your mould needs to be stiff, laminate ribs on the back to stiffen your mould up.

Finally slap you gelcoat and glass in the mould and knock out you moulding.

I very useful book to down load of the net is MARINE COMPOSITES BY ERIC GREENE ASSOCIATES. Its free and is packed full of useful practical composite info. I recommend it as all composite books are very exspensive.

I hope you suceed. Remember you learn from experience so start small and work bigger.Do a couple trials. I was 12 when I first made my own mould. Several years one, i work on some great projects making all sort of things.

Best of luck

Shaun

I would like to know more about the process of building the multi-part mold for the front end of the Shelby Cobra? I have a 92 Pontiac Grand Am that I want to modify, I think it has a sleek look that might make something interesting If I could just get that junky stock molding off, and some sleeker stuff molded and fashioned for the front and rear and sides, thanks, Jerry

[taobsu]

Originally Posted by Shaun

....

Firstly you need some male plugs. Foam and wood is the best, as its cheap, easily available (i.e. from building sites), very easy to shape etc.


Shaun

What kind of form to use? Where I can get them (manufacturer). I heard some will resolved when you put gelcoat/resin on. What kind of form are better to achieve class-A surface? If the plug making is to be automated (5-Axis milling) what are my options?


Thanks.

[MaxPower]

Hi Daz
I build prostock racing bodies and would like to offer some advice.
I build most of my bodies with carbon fiber and kevlar for wieght reasons.
Fiberglass will work fine if your not concerned with small gains in vehicle performance. I design my own custom plugs and make the molds and parts.
Basically I build the bodies from start to finish with excellent strenght appearance and wieght. Two of my bodies are currently on two world record holding cars.

I would be happy to offer some help if i can.

Good Luck