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Old 12-16-2011, 09:22 AM   #1
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Any fibreglass experts in the house?

OK, so I started a project I can not compleat

I thought the price for these things were a bit high and as I only want one for the air intake side and it is a racing car - I figured I would do it myself (or at least try to!)

I did some reading and understood that the best way was to make the initial shape with foam and that is what I have done - but now I am not sure about the next step?

Do I just cover this with fibreglass and then scoop out the foam?











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Old 12-16-2011, 10:05 AM   #2
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If you are happy with the shape you have, it would be prudent to start off by filling the voids with bondo, sand and shape to back to smooth and then begin the process of laying glass.

From what is seen in your pictures, you appear to be very close to a final size you are wanting to end with. This will be a problem as you lay glass and resin you will build up a considerable thickness. You should consider giving yourself at least 1/8 to 3/16 of an inch of room for glass build up and then final sanding and finishing.
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Old 12-16-2011, 10:09 AM   #3
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Not an expert .. but I do play around with this stuff in my spare time .. my lesson learned was that its an exercise in false economy. I'll spend more $ ( tools, material, ruined clothing ), hassle ( dusty garage, chemical smell ), and time making something than just buying it. The pro shops have tools ( autoclave, infuser, ect ) and molds to crank this stuff out quickly on the 'cheap' with 'decent' quality.

However for me, its become a hobby, I enjoy the process and like the fact that I 'made it myself' .. more pride of ownership for me. Plus I can make things exactly how I want it to be .. things that's not yet available .. like a 918 front bumper for the 986. =]

What I see here is that you taped up your existing piece and poured foam in the opening, then cutting it out to form your shape. This forms your 'plug' and is the first step to creating a mold if you wanted to create more than 1 copies of the new part. However, the problem with your 'plug' is that all the surfaces are very unfinished ( tape lines, ect ) and will show through to your mold and finally to your finished part.

If you wanted to go for a 1 off piece, that's a problem too .. You cant just lay glass on top of this anyways, the tape would prevent all adhesion to the actual piece, so the only thing the glass would actually stick to is the foam ..

Hate to be the bearer of bad news but IMHO, its a redo. Hopefully I'm wrong and some other expert chime in.
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Old 12-16-2011, 11:43 AM   #4
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Thank you both for the feedback and good comments. Sounds like I have demonstrated that a little knowledge and no experience is indeed a bad thing, and I have to scrap what I have done and would be better off just purchasing the finished product...

I do like the fact that I can at times say "I did this" and how do you learn if you do not try

Better luck next time
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Old 12-16-2011, 12:16 PM   #5
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Don't let it discourage you. We all start somewhere. Its quite fun once you get the hang of it .. atleast that's what I've been told .. I'm still learning too. ;]
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Old 12-16-2011, 01:10 PM   #6
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If you lay the glass cloth over the foam and epoxy or resin it. It will stick to the foam. You need to entirely cover the foam mold with release fabric so it'll release after it cures. For something like this it's best to vacuum bag it. Too bad you are far away or I could help you out. But again it's cold here so the resin has jelled. Look around for boat builders as there are some in Finland and they might be able to help you out. Check f-boat forum in yahoo.
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Old 12-16-2011, 01:32 PM   #7
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like a 918 front bumper for the 986. =]

I'd like to see this!!
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Old 12-16-2011, 02:05 PM   #8
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An alternative you may want to consider is thermal plastic for forming and working with. I have used this in non-heat environments for racing bikes for years. Simple to work with and a great starting point for custom pieces.
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Old 12-16-2011, 02:33 PM   #9
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Just in case you decide to buy them... I would at least try to make them and then you can always buy them if they dont turn out.

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Old 12-16-2011, 02:37 PM   #10
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You know I called Kokeln before twice and spoke with the girl there ( receptionist? ) .. both time they said someone was going to call me back .. both time I got stood up. Go figure.
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Old 12-16-2011, 02:40 PM   #11
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I would call them back and politely tell them that this is the third attempt to do business with them. Let us know how they respond. I like their stuff A LOT and would like to buy from them.
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Old 12-19-2011, 01:51 AM   #12
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So, maybe not perfect or show-car quality. But as a first attempt and for a racing car I am happy with the results

Still need to do a few more rounds with filler primer and sanding, and then paint...







In the pictures, I can see that the leading edge is not perfect, but in real life it does not look that bad. And like I said, I am happy to be able to say "I did that" and it is going on a racing car after all

Plus, it cost me a lot less than it would have cost to get one from Kokeln with shipping to Finland and all the imports costs
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Old 12-19-2011, 03:05 AM   #13
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Damned nice job so far, keep at it!
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Old 12-19-2011, 03:54 AM   #14
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Outstanding job! Nothing better then making it yourself and seeing it turn out well. Will be interested in seeing your thoughts on performance once mounted.
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Old 12-19-2011, 05:26 AM   #15
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Very nice work. I've worked with fiberglass before and it sure wasn't a pleasant experience, so I tip my hat to you.

Just out of curiosity, how much are the scoops from Kokeln?
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Old 12-20-2011, 03:20 AM   #16
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Thank you all for the nice feedback, makes me feel better about the results.

So I have painted it, but still need to do one last wet-sand on it and decide how I will finish off the inside. But once that is done, then I will say that this little project is completed

I decided to paint it black, and rather happy with the results. I will probably paint the one on the other side black at some point to match.


















Quote:
Originally Posted by Mark_T View Post
Just out of curiosity, how much are the scoops from Kokeln?
I have no idea. They do not list a price on their web site, and they have not answered my email...
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Old 12-20-2011, 08:02 AM   #17
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I think you have a future in fiberglass fabrication, my new Finnish friend!

Say that five times real fast
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Old 12-20-2011, 08:05 AM   #18
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How much and when can we get them?
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Old 12-20-2011, 09:10 AM   #19
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You are all to kind and I appreciate the complements, but I do not think I would be willing to make these for others to purchase.

The quality is not what I would say as product perfect, and include to that the fact that I only have one for the air intake side and do not even plan to make one for the other side.

But you have got me thinking...

I might get a mold made from this part, so that I can make it again if I ever get it damaged in a race.

But I have now got the confidence to make other stuff for the racing car in the future - already planning a complete redesign of the air box to make a true cold air intake system

Next on the plan for this part is to cut away some of the plastic that fits into the car. I have noticed that the air scoop does not line up with the tunnel to the air box and as such not giving ultimate air flow all the way to the filter. This I will try to fix - hope to have an update tomorrow...
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Old 02-04-2020, 04:40 PM   #20
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Reviving VERY old thread

Ok, Iím comfortable in admitting when Iím whipped and need some help. I still want a side intake like the one Kroggers built in this thread. I have also found two other examples (photos) on 986ís (another spec racer and a daily driver). All were slightly different but whole vents not just cheap stick onís so I know others have made them.

I get making the foam scoop and attaching it to the vent, no problem. What I canít get my head around is the process from that point. I cannot see how he got to his filled (gray) part from his initial taped up foam start.

Suggestions from those familiar with the fiberglass process on complex parts or just pointing me in the right direction is appreciated.

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