944Ross

Here is a video from the early '60's that may give you some moldmaking ideas...

http://www.youtube.com/watch?v=WNGVWWJrZls

V2Rocket

i used a bandsaw lol

krystar

nothing says old school design as much as a slide rule and a compass

NYFlapjack2

I laid out 36" wide wax paper sheet on the bench... laid on my cloth (pre cut & fitted) then 2 part mixed the West Systems Epoxy - from Marine supply...

Poured it on & saturated the cloth...laid another piece of wax paper on top and then rolled out with a Kitchen rolling pin...moved to edges out all the extra liquid epoxy.

You are left with no voids, and no excess (read weaker) straight liquid epoxy to puddle or bubble later, or worse sand out to a gaping pit mark.....place this wetted & wrung out sheet on your pattern or wrap with it etc.....

I did this for multiple fiberglass weaves (you familiar there are multiple options? and carbon fiber materials too) on the avatar... in the airplane world the strongest composite joints have little see through apparent thick epoxy sections between weaves of material.

Peel Ply is another neat item....it works well for wrapping wetted glass cloth then peel ply wrap over it to make a very smooth lay up for far less sanding to a finish......

Mike C.

A euro-style bumper without the light openings would be nice if you can keep the price low.

spannernut

as i have just registered,i reckon this is as good a post to comment on and let you all know i am here !!!
anyway i find this gprs moulding very interesting,but i was just curious as to one very important part that seems to be missing in the plans,
THE GEL coat !!!,also use mould release wax,if you dont use gelcoat prior to matting,you will end up using a lot of filler to ensure its smooth,prior to painting,PLUS IT GIVES ADDED PROTECTION FROM THE ELEMENTS.