Thread: Project $ 3 K Is Underway

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Yeah, Dan actually made the same comment about just going over the aluminum, but I think it would come out too bumpy. Plus, I have never built one of those molds you see where they cut pieces of plywood, put them every so often, and join them together with slats of wood. I have seen entire cars built this way, and want to see how it is done. So it is kind of an experiment too. Somewhere down the road I would like to build a one off, fiberglass sportscar body, and this might be good practice.

Don

That thing Looks hugh in there!!! I know that you have hugged the tranny as close as you dare but How much room do your feet actually have? I guess that a big guy don't have a chance fitting in one of these huh?

Good thing I used to be a ballerina, huh?? Not as bad as I thought it might end up, but I will have to wear regular tennis shoes instead of the wider one I usually wear. By keeping the door upholstery thin I should be ok, but it will be left foot brake, right foot gas for sure. Good thing I normally drive this way, a throwback to streetracing days.


Don

Don.
Looks great.
Remember the lost foam technique I told you about previously?
Well you are essentially doing the exact thing using the plywood.
My suggestion is get some 1" or 2" foam sheets from the local lunber yard used for insulation (they are usually 4X8')
Cut them down as you would the plywood mentioned earlier.
Bond them together with 2-sided carpet tape and shape to your desired contour, now you have your mold.
Glass over the mold.
After the glass has set, invert the body and gouge out the foam (no parting agent needed). Whatever foam remains, wash out (dissolve) with Acetone or Laquer Thinner.

Wa-lah!!! You're done. But with 1/2 effort and time !!!

Don
Your hump is looking good! WAY more elaborate than what I did.
Have you thought of adding a sloped toe board? The interior insert that came with my body has one and it makes a big difference in foot room. I can post a pic tommorrow if your curious.

You are right about glassing over the covering being rough. I made ribs out of 1" lumber and covered it with thin aluminum roof flashing. I then glassed over that. The glass didn't stick to the aluminum and it was easy to remove from the bottom. The top surface will need some more finishing.

Didn't mean to hijack your post.

Mike

No hijack Mike, that looks really good. No room for the toe board, but I can see where it would help.

Tom, tell me again about this foam thing. Do you build a solid shape like a big block, or just foam every so often? What do you carve it with, like maybe an electric carving knife?

I'm interested.


Don

Don,
I'm not trying to hijack either but I used Styrofoam from a arts and craft store. It comes in all sizes, anything from 3"x3" to 2"x4"x 48" sheets. They even have Styrofoam glue. It really makes it easy to shape by gluing the rough shape together then carving it exactly with a electric knife then with a file then sand paper. Just another way of doing it. I then use wax paper taped to it so it is easily removed no sticking.
Ken

Ken, what you and Tom (Supa Roosta) are saying makes a whole lot of sense. We have an arts and craft store on the way to the shop, think I'll stop tomorrow, and if they don't have it, there is a Home Depot a few blocks from the shop.

I like this idea you two have given me a lot. Thanks.


Don


BTW. I don't want anyone to EVER worry about hijacking on this thread. If it wasn't for all the contributions so many of you have made, it wouldn't have been any good or fun at all. Please keep it up.

You basically make it into a big block.
You could use the existing aluminum bands as templates.
Using the first band for the for the first two blocks as example. And cut the shape using a electric knife or coping saw . Continue with the following bands section by section until complete. Joining the blocks as you go with the 2 sided carpet tape. After it is all bonded, shape with a rasp and finish if you wish with 80 grit.
Remove the body from the frame. Set the mold in place and glass it in.
Remove the foam and wash/dissolve as needed.
Done!

D***, I was really looking forward to another few days of backbreaking work too. Thanks again for this suggestion, I think it will make it a whole lot easier guys.

(now what am I going to do with all the extra time I have left over )


Don

Originally Posted by Itoldyouso

D***, I was really looking forward to another few days of backbreaking work too. Thanks again for this suggestion, I think it will make it a whole lot easier guys.

(now what am I going to do with all the extra time I have left over )


Don

Glass up a Teardrop trailer body using the same technique! nykuck,, nyuck

Originally Posted by Supa Roosta

Glass up a Teardrop trailer body using the same technique! nykuck,, nyuck

Start painting that should keep you busy, fly out here and help me. God knows I need it

No Ken, I've seen your rod. You are doing just fine all by yourself.


Don

Originally Posted by brianrupnow

Ken Thurm---Nah, I'm letting Don be the "buildmeister" for now. I build a hotrod about every 10 years, and since I built the yellow roadster pickup 3 years ago, I should be good for another 7---and then I'll be 67, and too old to build another anyways. I built that 27 T about 11 years ago. I don't really have good garage facilities where I live now, and even though I built the roadster pickup here, I layed awake till 3:00 every morning for a year, afraid I might have set the garage on fire welding---and the garage is under the front bedrooms.----really---I doubt that I will build another hotrod in this lifetime.---Brian

Sorry to hear that! I think you are a true Hot Rodder. I really hope you change your mind some day, innovation is a terrible thing to waste.
I belong to a car club with 26 members. They are really some of the who who's in this industry. I just turned 60 in January and I'm the second youngest member. So maybe it's not to late.
Just a friendly thought, Brian.
Ken

Brian and Don: Thanks for the help on posting pics. I had clicked on "go advanced" before, but never scrolled down far enough to find "manage attachments". I knew someone here could straighten me out...

Don: More great looking work! It's almost a shame to cover up all that nice woodwork. Have you considered doing some wood trim work in your interior later? I have a wood dash in my coupe that draws lots of comments and compliments.

I have finally begun work on my track-style T. I picked up the turtle deck and a sprint car nose at Daytona last Saturday and began fabricating my frame Tuesday. When I get far enough to show something, I'll post a pic (or start a thread?).