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 Carbon mold/tool for lower&upper enclosed velo
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carolina
recumbent guru

USA
843 Posts

Posted - 06/12/2018 :  17:24:41  Show Profile  Visit carolina's Homepage  Reply with Quote
Stopped today and built in this inch top flange, “tilted” in bondo rear plate there in photo below. Flange holds the back of rear cover between wheel wells. Bondo with carbon layed inside the flange. I use polyester resin on plugs since only used one time,, (dry in 2 hours so i can start another area).

Globs of bondo and sanding, i use steel files on bondo too and profile gage some areas.

This plug will make a 3 piece mold, this back vertical plate will be the 3rd piece. Other 2 pieces split on belly plate, splitting the two wheel wells in haf. But whole part will be one piece. Clear duratec used as gel coat. Wax and pva as the release of part.


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Inside of WW’s will be clean and protected by duratec since this is male mold. No deterioration in WW’s by weather, dirt,etc..
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velosRus.com

Edited by - carolina on 06/12/2018 17:33:31
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carolina
recumbent guru

USA
843 Posts

Posted - 06/15/2018 :  10:44:45  Show Profile  Visit carolina's Homepage  Reply with Quote
What you may or may not like about making plugs with no cnc. Lots of body work. Upol bondo and finishing glaze and sikkens kombi putty. (Ebay or local). Belly ready for duratec, then up in top of WW’s/wheel wells.



Getting to where i can spray good enough for amateur. This is a plug, not a mold and not a part.


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velosRus.com

Edited by - carolina on 06/15/2018 12:06:52
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carolina
recumbent guru

USA
843 Posts

Posted - 06/15/2018 :  13:26:32  Show Profile  Visit carolina's Homepage  Reply with Quote
Got a thick first coat on of duratec on front two wheel wells to preserve them for many more unibodies. Already did rear bulkhead.


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carolina
recumbent guru

USA
843 Posts

Posted - 06/16/2018 :  06:25:01  Show Profile  Visit carolina's Homepage  Reply with Quote
Working my way up on each wheel well:


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warren
human power expert

USA
6265 Posts

Posted - 06/16/2018 :  12:48:26  Show Profile  Visit warren's Homepage  Reply with Quote
Looking good!
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carolina
recumbent guru

USA
843 Posts

Posted - 06/16/2018 :  20:59:31  Show Profile  Visit carolina's Homepage  Reply with Quote
Thanks, moved lil further along with both WW’s today. Getting short on micro-balloons/order monday.
1) have light grey ever coat
2) have quart of dark grey duratec coming
3) confidence in my spray painting is great.

Really happy with sprayed front wheel wells in big orange lower mold.
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Don’t use 2k primer on molds for restore. Use only duratec products and that ever coat light grey is from the same polyester family. Always epoxy over polyester, never polyester resin over epoxy. So u see most big molds are polyester/orange tooling gel is the poly family. Your part is carbon and epoxy resin. 2K primer is from neither family. Duratec products with pva or mclube and your part want stick.
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If one can make a plug they want, the rest is dow hill.
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velosRus.com

Edited by - carolina on 06/16/2018 21:00:59
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carolina
recumbent guru

USA
843 Posts

Posted - 06/17/2018 :  12:27:01  Show Profile  Visit carolina's Homepage  Reply with Quote
Warren: put hardware back in this morning and found more adjustments to make. Thats the way it is always. Keep hunting and making all fixtures and hardpoints best. Mr oxindine taught me sheet metal here 9 months on rv-4. He had taught me this and many other techniques. Dividers, and calipers, seemstress soft measure tapes really help amateur categories.

Also this guy is great for simple techniques,,,subscribe and follow/hit the bell:

https://youtu.be/xTQWnOgVZAs
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carolina
recumbent guru

USA
843 Posts

Posted - 06/17/2018 :  19:21:40  Show Profile  Visit carolina's Homepage  Reply with Quote
Short vid: big plug for 3 part mold. Heavenly!

https://youtu.be/oFtN15c_sq4
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carolina
recumbent guru

USA
843 Posts

Posted - 06/22/2018 :  21:04:41  Show Profile  Visit carolina's Homepage  Reply with Quote
Plug movement everyday, YAY,, micro (glass spheres) and compositeenvisions dot com medium epoxy. Yard work/house work, ebay fenders/sold 2. Had a window Blocked up in my house. Located color of paint for doctors velo, probably travis will paint in week or so. Ral-1023 yellow. Changed frt window in velo to petg and took out makrolon. Looks like petg will take a licking and keep kicking. Makrolon will not. I say always use 0.30 even at lil higher cost or haf to order it.

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Edited by - carolina on 06/23/2018 20:10:14
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carolina
recumbent guru

USA
843 Posts

Posted - 06/27/2018 :  21:12:47  Show Profile  Visit carolina's Homepage  Reply with Quote
Filling & sanding, filling and sanding , filling and sanding ,filling and sanding ,filling and sanding ,filling and sanding, filling and sanding: Notha week, could be starting a 3 piece mold.
I brush on filler (duratec and ever coat feather fill) first few dry sandings. I put black pigment in sometimes so i can see flaws. Then get out spray gun, then wet sand. Try to get to 1500/200 then makes buffing easy. After buffing wash with hot soapy water and rinse. Then TR mold release hand wax/ebay. Plugs & molds are rewarding.



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velosRus.com

Edited by - carolina on 06/27/2018 21:25:06
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carolina
recumbent guru

USA
843 Posts

Posted - 06/30/2018 :  01:41:48  Show Profile  Visit carolina's Homepage  Reply with Quote
Your mama! Paddys pub , really nice last night. Gotta have a break sometimes. Lots of pretty girls.

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Edited by - carolina on 06/30/2018 09:28:46
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carolina
recumbent guru

USA
843 Posts

Posted - 07/02/2018 :  10:44:43  Show Profile  Visit carolina's Homepage  Reply with Quote
Now 2 good coats of duratec on. Now fine filling and light sanding. I use sikkens kombi putty.



If ya had big money you could get plug cut on cnc. Speed up big time.
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carolina
recumbent guru

USA
843 Posts

Posted - 07/08/2018 :  16:16:49  Show Profile  Visit carolina's Homepage  Reply with Quote
FOUR WHEELER:

Couple more layups inside plug that mold to top of wheel wells;


Ready to wet sand and buff, finish a few more thoughts first:


This is a plug for the 3 wheeler: “rear wheel well”



Brevity & misspellings rampant:
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velosRus.com

Edited by - carolina on 07/12/2018 17:03:21
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carolina
recumbent guru

USA
843 Posts

Posted - 07/11/2018 :  19:10:02  Show Profile  Visit carolina's Homepage  Reply with Quote


1 (black#) has whooped me couple days, made in posterboard, then bent metal @ airport. Metal piece 1 is a plug that i will pull mold from. 1,2,3 become 1 piece rear bulkhead and keeps all elements out and becomes stronger. Red 4, & 5 #’s are the rear wheel wells. New part from mold takes 12 screws.
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This aluminum plug with wood on it, then filled a lil’ with bondo later tonight. This plug should hold its shape clieco’ed in position. Then tomorrow will prep other side with duratec an polish, then pull a lil’ one piece mold from it. Put the wood on with U-428 from DOW chemical and used their dow primer too.



Finished spraying 3 coats of duratec grey, wet sanded to 1500. Now buff and pull mold is next step.


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Edited by - carolina on 07/14/2018 11:40:58
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carolina
recumbent guru

USA
843 Posts

Posted - 07/14/2018 :  11:44:52  Show Profile  Visit carolina's Homepage  Reply with Quote
More duratec on front wheel wells yesterday, now roll rotisserie over to chair position for wet sanding and buffing.


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Edited by - carolina on 07/15/2018 10:44:20
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carolina
recumbent guru

USA
843 Posts

Posted - 07/15/2018 :  10:43:10  Show Profile  Visit carolina's Homepage  Reply with Quote
Rear cowling in yellow single stage now, matching mirrors from netherlands. Travis will paint top next week.



Top next week then lower unibody.



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Edited by - carolina on 07/15/2018 10:48:54
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carolina
recumbent guru

USA
843 Posts

Posted - 07/16/2018 :  10:49:56  Show Profile  Visit carolina's Homepage  Reply with Quote
Ed miller and l riding around: good vid

https://youtu.be/FsjQj4Ee1kU
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