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.

[CustomIce]

For making a mock up i'd use a very hard foam that is able to support several times its own weight, so as it doesn't deform easily.

But then agian if you're going the whole hog, why not get some second hand bumpers and custom fabricate the kit rear end front using these as a starting point, build it up with the foam i mentioned then cover it with fibreglass to make it durable.

HTH

[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

[devilsden97]

simple answer: YES

[D-Man]

also, i like Bondo Brand fiberglass; its just easy to work with IMO.

material to create a skeleton can be anything. you can use empty beer boxes or your boxers; hell you could use your **** if you wanted!!

are you a first time fiberglasser? because if you are; or litely experienced, let me tell you the seceret to fiberglass work; "The hardest part about fiberglass, is staying sober as its drying."

i know some memembers are tired of seeing that, but i cant stress it enough; and when you get that resin all over the place; and it starts seeping into your mask and things start changing colors; you'll dehydrate and grab that beer for nurishment.... thats' cool, but after 20 min of drying time; your going to be trashed. Even if your not drinking, the fumes still f- with your head.

Brings me to my next point; SPEND THE MONEY AND BUY A FREAKING HIGH QUALITY MASK

i wish i had a gas-mask... i promise, you can never Never NEVER have too good of a mask.

This post has been edited by D-Man: Apr 15, 2008 - 10:52 AM

[carbondude]

D-man is on point. You the foam is the best way to go, as it is easy to sand an shape. I would use a heavy duty hot glue gun. I use it when I make my molds at work. I manufacyure carbon and fiberglass aircraft parts, eeevvveery day. Its fun sometimes. I would cover the car in sections . Use bondo to seal after you acquired desired shape then paint. When you get to that point I'll walk you through the rest. Are you intending on reproducing or doin a one off?

[CAMAricer]

Thanks for the great advice.

Yes, this will be my first time working with fiberglass. I'll be sure to take all the necessary precautions and get good EQ before I start. Also, I'm in no rush so this will be a weekend project that will stretch over a few weeks (possibly months). Basically I want to get some experience with fabricating parts (and have some fun while I'm at it too).

I've got a good piece of foam...should I get a heat gun to shape it (was confused on that point)?

BTW, I might pickup some cheap after market bumpers and cut it up into pieces just to get a feel of the dimensions and shapes that can work.

[carbondude]

i always sand 80 grit to start. cleaner and more control.

[carbondude]

Oh yeah another good point from dman, the styrene in the resin is nothing short of a free buzz where a vapor mask. Also if sanding the glass or grinding use a crap load of baby powder on any body part exposed. Exspecially your neck, it will clog your pores which keeps the itchy glass dust out. And you'll smell baby fresh.

[playr158]

I'm going to go with a better answer.

Since you are a first time fiberglass attempter START SMALL AND LEARN.
don't try and build a body kit off the bat. Pick something small and try to replicate it, then work your way up as you get more comfortable and better with the process and materials.

here is a pictorial type of explanation:













so yes you are too ambitious, but in time you can do it, but small first big later


This post has been edited by playr158: Apr 16, 2008 - 8:26 AM

[D-Man]

first timer? Dude, get some EXP elsewhere first. Build you a fiberglass box. Build your self a hood vent. Build yourself your own action-figure of yourself, but dont start that large.

Player; that was a new car's fabrication. A good example of how big a project could get. I think this guy is just wanting to save his money by fabing a near-replica of an existing kit. but if he wants to go all out, more power to him. Wont be fun though.

Carbondude, GOOD POINT ON THE BABY POWDER!! I never though of that... I alway get a longsleeve, gloves, ninja-mask and plenty of bandannas to cover all my skin up with. I never knew that baby powder would work the same Learn something new everyday!

[playr158]

thats not a new car thats just a body kit for the most part...but an extreme one...the processes are the same the differences are in the details.

"save his money" <----to achieve this he'd just buy an ebay body kit, making one will EASILY cost more

[airforceb2cc]

Player-
What is with all those lowerd minivans up there?!?! Soccer moms driving in style!!!

[playr158]

you got nothing on my van son!

[D-Man]

thats not a new car thats just a body kit for the most part...but an extreme one...the processes are the same the differences are in the details.

Fair enough.

"save his money" <----to achieve this he'd just buy an ebay body kit, making one will EASILY cost more

not really, Buying any ebay fiberglass

Thats like putting dollars in the blender and hoping it turns into a margarita. lol.

And fiberglass is pretty cheap. It's the labor that'll hurt you. Infact, i'm trying to get a memember to let me clone his rear splitters. It'll set me back about 30-50 bucks. (that includes the smokes and alcohol)

Then again, i already have tools; heating lamps, minor supplies, ect. But a 5gal bucket of resin will run you like $20-$25 at local shops. Then $8-$12 for hardener? $5-$8 for fiber-cloth. 9.99 for 12pk, 4.99 smokes, and uh; that's what i'd need...

A new guy, woah, i dont even remember the price of the tools i alread own...

i spent $80ish for my mask...
$12- walmart ghetto sander... (instead of hand application, the Peice of crap works perfectly)
45ish for a good sander...
baby powder is like what? $3?
saw-horses~ uh... $15-$20?

plenty more... but way better than throwing your money in the garbage with an e-bay kit that was formed incorectly. There is a reason that it's cheaper. That reason is that it wont fit your celi, or any car for that matter

Common plyr, you know that!

This post has been edited by D-Man: Apr 16, 2008 - 11:37 AM

[D-Man]

you got nothing on my van son!

nice van... it's a mobile stage?

the windshield lifts?

awsomeness~

[carbondude]

Starting small is always a good idea lol. I would suggest copying afew small things that are easy to replace. Like the tweeter pods on your doors, I made molds of them and made carbon ones. I have a big box of carbon we where throwing out at work cause we had a iso inspection and the lot numbers where outdated. Talk about right place right time lol. Fiberglass is easy to work with i've been working with it for almost 10yrs as a career and I said it then and will say it now,"if I can do it a trained monkey can" just need a lil artistic ability and every1 has that. Have fun with it tho. I want to do more on my car but have to wait, I am a nfs carbon freak so I will get all my ideas from that. My wife has placed my spending on a slim fast diet until we get moved into the new house which won't be built or 4 months. I tell her that she really has her priorities all backwards, Celi then house but she won't hear it lol. Have fun tho.

[njccmd2002]

small, but not that small..

[NightMare2914]

I think the idea says alot. But it's easier said then done. I'd def listen to them. Get some EXP first! i had a hard enough time just customizin my veilside kit, I just got in a wreck, and all my front end work went straight down the drain! Something to think about. I'm not customizin my new front end i got.

[CAMAricer]

Thanks for all the good advice. After some consideration, I think I'll start out by trying to replicate my invader hood. It's flat (for the most part) so I think I can get some good practice on this. Then maybe I'll try adding scopes/vents next.

I am fully aware of the cost associated with undertaking this project but it's not about the saving money that motivates me to do this. I just want the ability to work with fiberglass/bondo/carbon fiber and just thought that I'd start off by making a body kit.

Hmm...maybe I'll make side skirts...they can't be THAT hard to make, right?

This post has been edited by CAMAricer: Apr 19, 2008 - 10:29 AM