Anyone with an engine undercover please take a glance...(composite possibility)

[SideWinderGX]

Here's the picture I didn't upload of the paper mache stuff:

Here's what I did this weekend:

As you can see it's almost done, I need to touch up some areas and put in more filler, and sand down some other areas for smoother transitions. Laying down filler next to dried filler creates a 2 mm step or so that I need to sand down, but that's not too bad.

The splotch over on the right needs to be touched up, the high point in the center of the piece needs to be done, and the left-ish needs to be touched up with more filler so it's consistent. Tiny holes will be filled in once the entire piece is laid down to my satisfaction. Then the flappy ears, which shouldn't take long at all once everything else is done.

I've been using a little chisel while the filler is still hardening to chip away the edges of the mold, and also expand the area around the bolt holes that are prone to breaking.

Taking longer than I expected but I'm trying a different process now which is turning out a lot better!

 

[Mk3runner]

cool!

 

[enjoi.this]

Sidewinder you are the man! Cant wait to see the finished product

 

[Neodeuccio]

Looks like it's coming along nicely. Keep up the good work!

 

[supraguy@aol]

Your recliner is ugly as sin, and your plant is dead.
Other than that, good work on the mold.

:biglaugh:

 

[SideWinderGX]

Your recliner is ugly as sin, and your plant is dead.
Other than that, good work on the mold.

:biglaugh:

The recliner was my grandmas, we got it for free :biglaugh:

 

[projectsupra]

Why would you ever choose to build a mold like that out of body filler and newspaper? :icon_conf
A professor let you go through all that trouble and didn't explain how to make a proper mold?
Best of luck, it's going to be a lot of work.

 

[grimreaper]

Your recliner is ugly as sin, and your plant is dead.
Other than that, good work on the mold.

:biglaugh:

:biglaugh:

 

[SideWinderGX]

Why would you ever choose to build a mold like that out of body filler and newspaper? :icon_conf
A professor let you go through all that trouble and didn't explain how to make a proper mold?
Best of luck, it's going to be a lot of work.

As long as the outer surface of the mold is smooth and inert it really doesn't matter. I needed something cheap, quick and effective and body filler fulfills all three. The newspaper won't be touching the part at all, I just used that so I don't have to use as much body filler.

Tedious work but I enjoy it, thanks

 

[SideWinderGX]

It's done! For the most part...

Filled in the small problem areas with excess filler today and ground it down to where it should be, did this for a bunch of holes and areas so now everything transitions as it should. Ran out of time today to do stuff as hw is backed up from last week so I have to prioritize unfortunately...a few more things to grind down (redder areas) and a few more tiny holes to fill in (can barely see from this pic) and I'll be happy!

Phone sucks, but this is taken from the bottom left corner of the above picture, towards the center of the piece. That nipple close to the camera, plus all the bumpy looking pieces in the middle, are the holes in the undercover. Doesn't matter what they look like as I'll be cutting the fiberglass around them anyways, I just need something there as a placeholder basically.

After the rest of the grinding and filling is done it needs a light sanding with some sandpaper to make it smoother (30 mins if I stay on top of it) and I'll be ready to make it. The very tiny holes will be filled in with the wax I'll be laying down, not only for this reason but also to help with releasing the part.

The bad news is, I have to head to Letchworth Park this coming weekend for something, so I won't be able to actually clean it up and make the part until the following weekend. I'm ordering what I need tomorrow though, so that I'll be able to clean up the mold and make the part and hand it over to a few people for unbiased opinions.

Honestly I enjoyed doing this and even though I knew enough from the class to make this, I learned quite a bit diving headfirst into this like I did. I'm glad its wrapping up!

 

[suprarx7nut]

Whoa, cool.

 

[supraguy@aol]

I respect your persistence.