Carl Fausett

Pulling the mold! Truly the most exciting day in this project. The cribbing is done, the fiberglass is all set up, and all we have to do is get the mold stretched and off the car.

You’ll note that we set the cribbing aside and did not affix it to the mold just yet. Because of the shape of the 928, and the fender and cowling lips we had, we knew that we would have to stretch the mold out and up and over all those lips in order to get it to release. If the wooden cribbing was on, we figured there would be no way to do that!

Believe me, it was hard enough as it was. It took 3 of us (Ryan, Myles, and I) about 3 hours to work with wedges around all the edges and pop the mold.

The look on Myles face pretty much says it all.

Carl Fausett

The mold was laid into the waiting cribbing, and fixed to the ribs with fiberglass resin and woven cloth to give it the final strength it needed to hold its shape.

Carl Fausett

“No 928’s were harmed in the making of this film” Here is the car immediately after pulling the mold, and the guys removing the headlamp and fog lamp plugs to return the car to normal.

A little sanding and paintwork and this 928 can return to the streets where it belongs.

Carl Fausett

The finished mold is strong and ready to produce perfect, lightweight front clips for anybody’s race car.

I get the first one!

bd0nalds0n

Yikes, what a project. Looks great.

EC928NC

So Carl.... it there a curb-alert for the current nose? I dig the upper vents!

Lizard928

looks great Carl,

Any idea as to roughly what type of a cost we are looking at for a front nose section? I am considering getting one and modifying it for my purposes

bd0nalds0n

Where are the canards?

cold_beer839

Carl, do you ever sleep?!!!

dprantl

Wow, that is sweet! After looking at that, it looks like you could easily make a mold for the rear fender liners

Dan
'91 928GT S/C 475hp/460lb.ft

Carl Fausett

I'm still adding up the materials and labor and trying to separate what was making the mold (setup costs) vs what was making the part.

It looks like I will be able to offer the complete front clip in fiberglass for about $1300 (around 26 pounds) or in wet carbon fiber for about $2200 (about 13 pounds).

Rick Carter

Great contribution, thanks.

aggravation

Next time anyone complains about the end price for products developed for the 928 by you guys who make them I'm going to direct them to this thread.
R&D isn't just an excuse to mark up a product, it's a very time consuming commitment and a risky investment for the vendor.

Great job!
If I didn't own a 928 I'd think this kind of specialty work for a car that is out of production and so limited in supply was crazy...instead I know the 928 is worthy of the efforts. We are lucky you guys picked the 928 to be your pet project.

Lizard928

Well I REALLY like the weight of the CF, but it isnt as easy to modify, and the price is abit more than I would really like.

Let me know when this is ready as at that price I am very keen on the fiberglass one.

Charley B

What an impressive piece of work. Congratulations.