Wide front arches. Options

[yellowchinaman]

Only 20mm wide and is going to look subtle like OEM.

Why only 20mm??? Well here's an explanation from the GT4OC.
"There are several major benefits to this, for many people the main benefit would be fatter looks - but thats not the only thing. In stock form the rear arches have space to take much wider or bigger offset wheels than the fronts, with a 4wd system you really want to run the same width wheels all round so most people resort to running spacers on the rear to make it look better with the deep rear arches. The problem with this is that the rear track width is deliberately narrower than the front on the GT4 in order to help counter understeer, by making the rear track wider without similar increases on the front you will be increasing the car's understeer tendencies. This might not be noticeable on the road to many but if you start pushing it hard on track it can be seen alot more. Also there is the added benefit of removing a little weight from the heavy front end of the car (every little helps!), and replacing your rusty and dinged original wings with mint new ones.

Obviously the other great benefit is it will means a whole load more choice of wheels becomes available, so anyone with dreams of 10" deep dish JDM bling could be in luck."

So here's how we being.
First off we make a template using replica arches fixed exactly 20mide from the top edge of the arches.
Notice how these replica arches have the lines to retain continuity.





As you can see it's very subtle yet significant


Next off after I've sealed the arches with masking tape to ensure no leaks I'll start with the expanding foam.
TBC...

[bloodMoney]

Subscribed. I may be in the market for these if you decide to mass produce.

[yellowchinaman]

Subscribed. I may be in the market for these if you decide to mass produce.

This is being done as there is a demand for the GT4's to balance it's stance with it's rears.
They will be going into production next week.

Anyway here's the fun part with 2 part expanding poli foam. (Not the one's in the can)
So I started by sealing the gaps with masking tape to try to contain as much liquid foam as I can.
Otherwise it'll just leak out and go all over the floor before it expands.

2 part foam. This allows me to control the expansion and bubble density rate. There is a secret to proportional mix and also timing as to when to pour for different stages.



These two tape strips prevent the guided arches from pulling out any further when the foam expands. Without them, you'll have uneven widths.


Dont worry about making a mess



After the first filling had fully set, I can then remove the supporting tape and start the build up as high as I can for the blending.
Small layer by layer is built on top of each other.






once that's done and set after an hour or so, I started the rough carving







Then using 80 grit and sanding block, I started taking it back to get a smooth curve.







The foam needs to be taken back a few mm's more or deeper then what you initially want. This is because of 2 things.
1: Fibreglass filler is needed to be applied before fine filler so you can't have any foam being exposed.
2. The filler work wont happen till tomorrow because the foam may still expand.

As you can see I'm going for a subtle OEM look. Already it's looking more like a match with the rear arches.
Over the next few days I'll be doing lots of filler work skimming over and over again till it's even on both sides.
Once done, I'll quick prime it and smooth it down. Then we'll start with the composite moulds for mass production.
ETA on this wide front arches will be another 2 weeks.

This post has been edited by yellowchinaman: Sep 9, 2013 - 2:10 PM