Too ambitious?, Want to make my own body kit. Options

[CAMAricer]

I guess the first thing to do is make molds of my existing parts to use as a template...

Does anyone know what kind of material I need (or will need) to do this? What's the cheapest practice material I can use to learn how to do this? Thin aluminum sheets? Foam boards? Paper mache?

And where is best place for me to shop for fiberglass, carbon fiber sheets, etc?

Just last week, I used bondo for the first time and it seems to me that with enough practice (and money), anyone could create their very own body kit out of these materials.

[D-Man]

oh, okay. I'm a very experienced & talented fiberglasser~ And FYI, i'm not willing to attempt to fabricate our bumpers.

But, if you wanna take a swing; then be my guest; i'll tell you how i've done OTHER cars bumpers. (there is just too much action on our fronts for replication; IMO)

you going to want to goto michals or hobby-lobby and pick up the large (green) foam sheets; they bend when heated. Or you could use sheet metal: to create the bottom of this kit. Attach it right onto your bumper. How you choose to do that is up to you, drill, glue, whatever~ Also, how you decite to fourm it is also up to you. this bottom part is all coming out of your head; so i cant tell you how to make it what you want it; but it's just a skeleton.

Tape the whole thing up using the blue painters tape. I mean COVER every single inch; and dont forget about the rear lips that hold your fender bracket on, you'll need to fabricate theese into your kit; or it'll never mount.

Mix up your fiberglass, (small amouts at a time, the **** drys fast; if you want it to stay wet ) lay a light coat of resin/hardener only; and after it drys remove it and begin glassing inside it.

IMO; the knitted sheets; 4-5 layres would be perfect, Using a mixture with light hardener; so that it maintained a level of flexibility like polyurethane; but keeping it strong enough to hold up to all the elements; and high speeds. (130+) if you wanna go with the shreaded-squares to make it hard as a rock; that's your decision. Just make sure you lay it evenly or i'll look like schett.

when your done there; sand it down, and coat it with Body-filler. (bondo) Then sand it down again. Rinse and Repeat untill it's flawless.

Goto Home-Depot and rent a spray rigg, ShermanWIlliams for some paint. Spray it up.

I've replicated MANY parts; and pulled many fabrications out of my ass; But i wouldnt dare take a swing at replicating our bumpers. Nope...

Dont forget to take pictures throughout the whole process; rather you succeed or fail, i'd like to see it; perhaps it'd give me the courage to take a swing at it.

Good Luck. If i can help you any more, let me know. I'd be happy to assist all i can in this project.

This post has been edited by D-Man: Apr 15, 2008 - 10:16 AM