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Sept 15, 2019 19:40:35 GMT
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Didn’t finish, but don’t want to lose post... more later  Taps fingers in impatience... Hopefully you’ve found better things to do, as it’s all downhill I’m afraid  Next step, painted on the gel coat  And then when that was almost dry (tack dry ?), started on the fibreglassing  By which time it was getting late, and was dark! So this morning, we checked it over and we had a few bubbles between the gel coat and the fibre glass, and I was starting to doubt my previous belief that the pulley cover would come out (turns out my doubt was right) Here it is this morning, with excess trimmed  We tried to separate and struggled, this mould isn’t strong enough, we should have carried on building up a couple more layers, but that would have made it even harder to separate We broke it getting it apart, but please with how well the louvred have come out  There are a couple of bits where the gelcoat has travelled into the filler and then shattered when being separated  But overall worked quite well. We were a bit thin with the gel coat in places (it was suggested you could apply 2 coats of gelcoat, so probably do that)  And we’ve ordered a couple of flat epoxy grp sheet to make a split mould. So we’ve learned a bit about fibreglassing  |
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Sept 15, 2019 19:43:39 GMT
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I have used wax as mould release and it works very well. Apply it with a piece of cloth, let it dry for an hours and then wipe it with a clean piece of cloth. Best is to repeat this proces. After wiping, you cannot see the wax but it works well. I also use a kind of plastic clay that does not harden for mould making and filling thread holes. You tube also has a lot of videos about mould making Peter Thanks, we will try the wax next time then I was also told that blu-tac is good for filling the holes, which I guess is a type of plastic clay stuff Will research that a bit more, as some of the gel coat bled into the filler in the louvres |
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Sept 15, 2019 19:48:09 GMT
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Also, we got a cheap Chinese breather box  It’s got 4 connections, so we should be able to breath bot heads, the fuel pump block off and the oil filler. And is 1.2ltr so larger  It’s crazy, it was cheaper to buy this than to buy threaded bosses, fittings and hose separately! The fittings are probably rubbish, but they are only there for a bit of air and oil vapour |
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luckyseven
Posted a lot
Owning sneering dismissive pedantry since 1970
Posts: 3,839
Club RR Member Number: 45
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Sept 15, 2019 19:55:04 GMT
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I'd call that first attempt at moulding 'glass a qualified success  You can build up an aftermarket parts empire from here and then sell it to the Chinese in a few years and retire [/EMPI] |
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Sept 15, 2019 20:22:09 GMT
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you could use any flat smooth material to make a flange edge around the face of the cowl. lay up the side section , remove form , wax and then lay up louvered section. a nice simple split mould. another option with a piece with parallel sides like that is to incorporate a valve stem somewhere and use air pressure to aid releasing the plug and any pieces from mould.
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'80 s1 924 turbo..hibernating
'80 golf gli cabriolet...doing impression of a skip
'97 pug 106 commuter...continuing cheapness making me smile!
firm believer in the k.i.s.s and f.i.s.h principles.
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Sept 15, 2019 22:26:22 GMT
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Plasticine is excellent for filling areas like louvres or front grilles when fibreglassing. As said, an airline squirted in will pop it out nicely.
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Sept 16, 2019 4:56:44 GMT
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That clay is called plasticine like Mark mentioned. It is also very usefull to fill the gap between the cover and the temporary surface during mould making. A very usefull You tube video for me was
I did the mould making like they described and it worked well.
Looking at the shape of your cover, it may be better to make a 3 piece mould as the sides run straight down and this will never release well as there will always be a small amount of shrinking in the curing of the polyester.
I do 1 thick layer of gelcoat, then 2 coats of vinylester resin with 2 pieces of 220 grm and then 4 layers of 450 grm with polyester laminating resin. I sometimes use a rubber hammer to free the mould from the product
Peter
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Darkspeed
Club Retro Rides Member
Posts: 4,880
Club RR Member Number: 39
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Sept 16, 2019 7:28:00 GMT
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Not the easiest of shapes to start with. That looks like a candidate for a 3 piece mould - top and 2 sides. Louvres are a PITA as you have to really avoid any cut backs to ensure that they release. Parallel sides near always need a split mould due to the way the mould shrinks onto the part - otherwise you destroy the buck getting it out and then the same with the part!
I use a foam brush for the application of PVA and then I will still wax the PVA to be sure. A sheet of 3mm poly would be good to assist with making the mould as its great for shutters.
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Last Edit: Sept 16, 2019 7:30:06 GMT by Darkspeed
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Erm... hello again Not been on here for a while it seems. No real reason, life got a bit hectic.... it seems to have rained every time we’ve got near the Fug. Been on various uni visits with Ella (where possible using the Corsa )  I mean,just because it looks expensive doesn’t mean it will be expensive, right? Anyway, I have a plan for that that won’t eat into the Fug Lucy changed jobs and now works days occasionally, this probably sounds bizarre, but having worked part-time nights for the last 17 years, now working some long days (8-8) is a real cultural shift! I have to cook dinner and stuff  We’ve been doing stuff, but only bits and bobs and I kept thinking I’d save up until there was something worth posting (not sure we’ve got there yet... but here it is anyway ) So found some cheap Cappuccino seats on eBay, another £40 and about 60 miles away... but had a job down that way a week or so later so agreed with customer, paid for them and eventually collected  There are a couple of rips in them, and they need some attention, but didn’t want to be spending loads of money on something that we don’t even know will fit seems a bit silly   Fox Picture! They don’t fit oh well, they are a lot closer to fitting than the Copen ones (that I still haven’t sold because... meh... life!) So will keep these and sell the Daihatsu ones! No really, I will! Apologies for the gloomy shots, but it keeps blooming raining and is an exact fit into the shed... so putting away in a hurry is a bit tricky! One of the carbs had a bit of play in the spindle shaft, wasn’t noticeable when we worked on them, but is now... either we just missed it, or when we fitted the CSP linkage we found a edge of good surface that worked on the bench but soon gave up  Because of weather and strictly, we got upgraded to being allowed to rebuild it in the kitchen though  And back on!  The other thing we’ve done is fit electronic ignition, looked at various options and settled on the Pertronix a while back, was waiting to be able to get the billet dizzy, but they are a lot more money, and the points were not behaving, so have fitted an Ignitor 3, chose the 3 over the other (cheaper) models as it has built in rev limiter  And of course, the flamethrower coil to match  So hopefully the sun will keep shining long enough for us to go and set it all up! |
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luckyseven
Posted a lot
Owning sneering dismissive pedantry since 1970
Posts: 3,839
Club RR Member Number: 45
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Oct 20, 2019 11:40:01 GMT
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Same ignition gubbins as I got in mine, seems to work well. Despite internet stories of rubbish quality, breakages, rough running, imminent death of nuns and kittens, etc etc. Feel your pain re the weather. I've now reached the point where I have to drill a hole in the bottom of the door to stop it filling up with water  |
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Oct 20, 2019 17:22:11 GMT
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Same ignition gubbins as I got in mine, seems to work well. Despite internet stories of rubbish quality, breakages, rough running, imminent death of nuns and kittens, etc etc. Feel your pain re the weather. I've now reached the point where I have to drill a hole in the bottom of the door to stop it filling up with water Nick, there should be holes there already. Problem occurs as the door bottom is replaced, the new piece doesn't have the holes, so it rusts out even quicker... |
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1968 Cal Look Beetle - 2007cc motor - 14.45@93mph in full street trim
1970-ish Karmann Beetle cabriolet - project soon to be re-started.
1986 Scirocco - big plans, one day!
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luckyseven
Posted a lot
Owning sneering dismissive pedantry since 1970
Posts: 3,839
Club RR Member Number: 45
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Oct 20, 2019 17:38:30 GMT
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Same ignition gubbins as I got in mine, seems to work well. Despite internet stories of rubbish quality, breakages, rough running, imminent death of nuns and kittens, etc etc. Feel your pain re the weather. I've now reached the point where I have to drill a hole in the bottom of the door to stop it filling up with water Nick, there should be holes there already. Problem occurs as the door bottom is replaced, the new piece doesn't have the holes, so it rusts out even quicker... Yeah, that's what I figured. The passenger one has a hole... I found this out in the hot weather when the waxoyl in it melted and gooped out onto the running board. The driver's door doesn't... I found this out recently since it started raining every single bloody goddamned day and the door now sloshes loudly every time it's opened or closed Not sure if it's ever been changed or welded... doesn't seem to have been but I can't find a hole or any trace of one so who knows? |
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Oct 20, 2019 19:57:35 GMT
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Doors?! Yeah, the Pertronix went in very easily, and worked straight off, we just needed to tweak the timing with a strobe. So fingers crossed but we put the points in the tool bag just in case. We drilled the fuel blanking plate for a hose spigot  Started setting up the carbs today, using the book. But we have a slight misfire on no. 4, we managed to adjust it out but when trying to set up the idle circuit, winding the air bypass in on this carb doesn’t seem to make a difference, so will whip the carb off and investigate. It is very rich on the idle circuit though, so wondering if we need a smaller jet. Which we ought to change whilst we have it in bits to clean etc. Will pop up in the week and take the carb off and have a look. But ordered a couple of aerosol cans of air to blow it out, so will wait for them and then check the jet size whilst doing that. |
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Hmmmm not much of an update, But we haven’t had a weigh in of scrap for a while, so had a quick sort out last week and took a load in  and sorted the rest over the weekend  Which is bagged up ready to weigh in on Wednesday The reason to get it sorted, is hopefully to get a deal at the NEC over the weekend |
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jamesd1972
Club Retro Rides Member
Posts: 2,921 
Club RR Member Number: 40
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Deal on what ?!
James
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Nov 10, 2019 21:25:00 GMT
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So had a second weigh-in last week... I had some work taking out some shop fitting electrics, so went to scrappy first thing and got another £175. Then went to the job and pulled out another load of domestic cable, so popped back (as I was still only a mile away, and we had only just tidied the garage) and got another £40 We haven’t actually done much work on the Fug, but have a few projects planned for the winter; Finish sorting out the engine Take it out and put a few miles on it Take it for a run up the strip at Santa Pod We have a new set of graphics for next year We need to finish fitting the oil breather box, and need to make a bracket for that And we want to make a box for the electrics, for behind the dashboard... the easy option for that would be to make a template for that and get someone to fabricate it for us. Buuuuutttt, if you’ve read this thread you’d know that quite often we poke the easy option in the eye and do something else. And this is no exception to that So, after poring over the internet whilst Lucy was working night shifts.... NO! after 17 years I’m fairly bored of looking at that*! I was looking up tools, specifically tig welders, and after reading the tales of woe about Chinese welders (you don’t get many rave reviews... only the rants about the bad stuff) Anyway, after some fairly robust man-maths we went to the NEC today. Tom was in school on Friday, Was my dads 75th birthday yesterday so couldn’t go on the Saturday. And today we had Remembrance parade this morning, so was a bit of a rush for a half a day visit. But then a mate gave us some tickets which sweetened the deal so we went, and we bought this!  OK, it’s probably not that actual one (and we were fairly glad that we didn’t have to lug it around with us anyway) But we’ve got a R-Tech AC/DC 160A tig welders, and evening got them to throw in a few bits too We had a wander round as well, didn’t take many photos as didn’t have the time to wait for the crowds to part for photo opportunities But an enjoyable wander round and then managed to save on the car parking too  That welder gets cheaper by the minute |
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Thyck
Part of things
Posts: 21
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Nov 11, 2019 16:25:37 GMT
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A Fug, wow how cool is that...a great project to do as father and son I had a Fug 2 a few years back that I spent years transforming from its' rather sorry state to a V8-powered satsuma...and promptly drove 1500 km's down to Le Mans and back...a great car for putting a smile on both your face and those of onlookers... I saw a post about seats...I managed to get hold of 2 S1 Lotus Elise seats for very little...they fit very nicely (at least into the Fug 2), potentially also with the runners if you really wanted them... It's looking great, keep up the good work!   |
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Last Edit: Nov 11, 2019 16:32:30 GMT by Thyck
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Just wanted to say thank you as this is one of the many threads that has kept me sane over the past few weeks.
Loving the learning new skills along the way and the way Tom is gaining experience and is massively shaping the direction of this build.
Hopefully when I have a sproglet he will be as keen to get involved and not want me to take him to football or something else terrible!
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That welder gets cheaper by the minute 
