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Let's Make a Radical Custom 928

 
Old 07-03-2018, 07:42 PM
  #316  
2ndtime928DAD
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Jerry, I just wanted to say the work you're doing on this project is thrilling to watch. I do have a question for you in setting up and building your forms. Having spent numerous years as a welder/fabricator, I am simply curious. Would it work to box in the corners, then cover the metal areas (plastic wrap, wax paper) then fill the in with an expanded foam (spray foam). From there you have an exact mold of the area. That can easily be fiber glassed to give it strength. I'm interested in your thoughts.

​​​​​​if this starts to clog up the post then by all means PM me.

Keep up the great work!!!!!
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Old 07-04-2018, 10:48 AM
  #317  
Jerry Feather
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A few strips of wood glued onto the left segment and one more on the front. Today I'll test fit them and then try to figure out the exact shape of the corners which are still driving me nuts. I glued some extra pieces of wood on the front corner where it appeared to be too loose and now have ground most of that off again getting it close to fitting. The rear corners are still kind of a mystery in regard to their shape, but I hope with continued testing the shape will finally come into focus.



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Old 07-04-2018, 07:08 PM
  #318  
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I keep laying pieces up in epoxy and then I worked over my make-shift work bench. I think I have the corners figured out. The problem I have been having with the rear corners is that I discovered that the headliner is not very close to the inner sheetmetal at the tops of the B-Posts. I cut the top corner off of one of my spare inside quarter panels and find that there is quite a large space between the liner and the metal. I think with that realization I'll be able to get the rear corners finished shortly.





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Old 07-04-2018, 10:17 PM
  #319  
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Now I can lay out the four pieces of the mold on my new work space and see how the pieces are going to fit together and begin to envision filling in the center.



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Old 07-05-2018, 10:59 AM
  #320  
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Now that I am beginning to notice how heavy each of the four outer segments of this mold are getting I become concerned about how much the whole thing is going to weigh when it is all glued together and finished. I am wishing now that I had had the forethought to cut chunks of wood out of the pieces before I glued them into place. I suppose I could still use a hole saw and cut holes in various places to help some, and I might, but hindsight is 20/20.
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Old 07-06-2018, 04:30 PM
  #321  
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Progress is movement in any direction. I'm making some progress with this mold, but it is sure taking time. I have covered the rear segment and am letting the epoxy set. I have fit the left side again and will need to put some more wood on it is the front since I ground off too much. I think the rear corners are taking shape pretty well.

As soon as I have all four segments closely fit I'll do the setting in Bondo to finalize their shape and them put some pieces of wood on the front and back to create the flair necessary in those locations.



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Old 09-04-2018, 08:03 PM
  #322  
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Jerry, how is this project coming? I had been following each step, looking forward to the finished project. I know your currently working on a new steering wheel, but I hope you haven't abandoned this one.
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Old 09-05-2018, 10:50 AM
  #323  
Jerry Feather
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Hi Jim. Thanks for staying tuned. No, this one is not abandoned. Right now I am kind of limited in how much time I can spend in the shop due to family issues, and I think that is kind of why I have gotten back to the steering wheel, since I can can draw circles and fiddle with it much here in the house, where I am kind of stuck. This isn't the place to go into the issues, but they appear to be kind of temporary, so don't give up hope that I'll be back on the custom 928 in a while.
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