Front fender on FJ1200 ABS

aj52 · October 21, 2016, 02:02:23 PM

Testing if photos is uploaded

aj52 · October 21, 2016, 02:12:24 PM

Got it,thanks guys.
Will upload rest over weekend

FJmonkey · October 21, 2016, 03:16:55 PM

Looking good. This pushes me to post my Bandit adapter bracket for the FJ... Kind of rough at the moment but Pat taught me a little about polishing AL...

aj52 · October 21, 2016, 04:30:18 PM

Considering the amount of work I've put in this far and is not finished yet,I think your silution is must better,FJmonkey.

If I knew when I have started the fibreglassing that it is going to be this much time consuming,I would have take you up on your offer you made back then,but I am about 80% finished with it.

It the will be finish by next week friday,painted the lot.
Next Saturday it is me,myself and I on the road to a ralley in Montaqu.

FJ was sitting for to long in the garage because of the fender

FJmonkey · October 21, 2016, 04:36:45 PM

Quote from: aj52 on October 21, 2016, 04:30:18 PM
Considering the amount of work I've put in this far and is not finished yet,I think your silution is must better,FJmonkey.

If I knew when I have started the fibreglassing that it is going to be this much time consuming,I would have take you up on your offer you made back then,but I am about 80% finished with it.

It the will be finish by next week friday,painted the lot.
Next Saturday it is me,myself and I on the road to a ralley in Montaqu.
FJ was sitting for to long in the garage because of the fender

I made a spare, would you like it?

Russfjr1 · October 21, 2016, 05:23:06 PM

Hi just having a look at this post, are you trying to smooth out the fiberglass matting you have put over the original rear to use as it's outer finish? Sorry it's not to clear on the post but if that's the case save yourself loads of time and wax up the inner of the mould you have made and cast another from the inside,,, it should be near perfect. Then carry on with your sound idea of creating the front half but using the same method. Hope this helps, if it is that I have got it all wrong sorry for adding my penith

aj52 · October 21, 2016, 06:40:22 PM

Quote from: Russfjr1 on October 21, 2016, 05:23:06 PM
Hi just having a look at this post, are you trying to smooth out the fiberglass matting you have put over the original rear to use as it's outer finish? Sorry it's not to clear on the post but if that's the case save yourself loads of time and wax up the inner of the mould you have made and cast another from the inside,,, it should be near perfect. Then carry on with your sound idea of creating the front half but using the same method. Hope this helps, if it is that I have got it all wrong sorry for adding my penith

Hi Russ
I used a mould release between mould and new piece.
Don't know if it is that you are talking about.
Thanks for your input

Russfjr1 · October 22, 2016, 02:54:20 PM

I will try again,

Using the original rear part covering it with release agent then laying up your gel coat, fiberglass letting it cure, pull them both apart I understand and it's the way I would have a go but I would then repeat the process using the inside of the new fiberglass rear you just created, again with copious amounts of release agent. Doing it that way you then have a mould you can use many times and the finished product pops out with a smooth exterior finish.

So you would use the original part as the "plug" your first fiberglass copy of that would become your "mould" to make as many as you like from said mold.

Sorry if I didn't make it clear first time. The process is what I am thinking of doing to the fairing I have made, polish it like mad, loads of release agent (carnauba wax) then lay up a gel coat over that followed by some fine matting with resin then a few layers of chop strand, the gel coat then becomes the inside of the new mould this you then polish again loads of wax and the the next fairing after being left to cure should pop out easy ... well that's the theory. Sorry if it's long winded just can't think of a better way to put it. At the end of the day I am sure it will all turn out fine whatever way you do it even if you end up making 2 or 3 it's all good fun coupled with the fact you made it yourself. That has to be the best bit. Russ

aj52 · October 22, 2016, 05:06:36 PM

Quote from: Russfjr1 on October 22, 2016, 02:54:20 PM
I will try again, Using the original rear part covering it with release agent then laying up your gel coat, fiberglass letting it cure, pull them both apart I understand and it's the way I would have a go but I would then repeat the process using the inside of the new fiberglass rear you just created, again with copious amounts of release agent. Doing it that way you then have a mould you can use many times and the finished product pops out with a smooth exterior finish.

So you would use the original part as the "plug" your first fiberglass copy of that would become your "mould" to make as many as you like from said mold.

Sorry if I didn't make it clear first time. The process is what I am thinking of doing to the fairing I have made, polish it like mad, loads of release agent (carnauba wax) then lay up a gel coat over that followed by some fine matting with resin then a few layers of chop strand, the gel coat then becomes the inside of the new mould this you then polish again loads of wax and the the next fairing after being left to cure should pop out easy ... well that's the theory. Sorry if it's long winded just can't think of a better way to put it. At the end of the day I am sure it will all turn out fine whatever way you do it even if you end up making 2 or 3 it's all good fun coupled with the fact you made it yourself. That has to be the best bit. Russ

Thanks Russ
I have done it the other way around,so that is why I've been sanding my elbows nearly to a standstill for days.
Wish you had read it earlier what I was doing.
Thanks a lot for your advice,will keep it in mind when I do fibreglassing again,because I sweared never again.

Hannes

PaulG · October 23, 2016, 07:06:29 AM

I think this is what Russ was describing. I've been looking at hours of videos on YouTube re this subject. That's why I was interested in your progress. Have a zillion ideas in my head re composite bodywork. If only I had a place to do it. Soon...

https://m.youtube.com/watch?v=3i0EkkAfFHI

aj52 · October 23, 2016, 11:32:47 AM

Some more photo's on my progress.
Primed fender is just to see how the shape is.

Please look pass the mess in garage

PaulG · October 23, 2016, 03:09:49 PM

Lookin great! What mess? It's a garage, not a maternity ward.

aj52 · October 23, 2016, 05:23:05 PM

Quote from: PaulG on October 23, 2016, 03:09:49 PM
Lookin great! What mess? It's a garage, not a maternity ward.

Thanks Paul
According to the wife it looks like a pigstay

FJmonkey · October 23, 2016, 07:03:08 PM

The fender is coming along nicely, I love to see these kind of DIY projects.

Russfjr1 · October 25, 2016, 12:33:07 PM

As ever with any bodywork or modifications to existing panels it's all a labour of love but when you get it right it all becomes worth it.
Now you have it in primer get another can of any colour and dust a very very fine coat on it so fine all you can really see is the primer then start to sand it with a firm backing pad between the wet n dry and your hand, with a firm pad used like that you will soon see any high / low spots to address. Sorry if you know that but just in case.

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Front fender on FJ1200 ABS