the start of my new amp rack.

[OisinT]

you made your custom box the same way?

[-=BOOMER=-]

I Havent made the custom box for this car yet but yes I will make it the same way. though when building a box you want it to be more rigid then just with the fleece, after you get your basic mold made then you use fiberglass to strenghen the inside of the box.
I looked for some links that show others making boxes but couldnt find them on this computer.

[-=BOOMER=-]

Today was spent mostly in adding on Bondo and sanding it back off till most of the surfaces are flat and smooth, and thus ready for a primer/paint. This is the part that allot of people don’t like to spend much time, but this is also the part that will make the biggest difference in if it looks professional or rushed.



This is the whole thing and its first Bondo layer.


This is a close up before I sand it down flat.


This is a close up after the sanding and before the second layer of Bondo. You can see the divots that still need to be filled, but its mostly flat.

[ci5ic]

Are you sanding that by hand, or using some kind of electric sander?

[ci5ic]

so... I go out to my car... duct tape off the area I'll be puring resin over...

Actually, I heard a really good idea recently, supposedly works really well for making molds like that. What you do is coat the surface you are molding with Vaseline. Then, you lay plastic-wrap on top of the vaseline so that it kindof sticks to the surface. Then, just fiberglass over it, and you don't even need to use fleece. The only drawback I can forsee is that cleaning up all that vaseling might be a little frustrating.

I was going to have someone build me a totally custom setup for my hatch area, and they wanted 2 grand to do it. So I decided that for less than $500, I can buy all the tools and materials and do it myself. I've just been experimenting with different ideas for making molds, but I plan to build my box soon...

One method I tried was using hardening expanding foam insulation to make molds of some of my interior panels. Spray the foam on the mold area, let it harden, pop it out and fiberglass the other side of it, then dissolve the foam with acetone. Good idea, but doesn't work. When the foam is popped out of the mold area, it doesn't hold its shape too well.

[-=BOOMER=-]

Originally posted by ci5ic
Are you sanding that by hand, or using some kind of electric sander?

By hand and its killing me.
well i do have a scotch pad that conects to a drill for mass removal but after that its all hand work.

[ci5ic]

Hey man, what happened? I was looking forward to some more pics? hehehe

[-=BOOMER=-]

last few days are all adding bondo and sanding off, ill take a pic soon but at this point it still looks alot the same.
till i finaly get exatly the shape i want and get it nice and smooth its kinda boring stuff.

[PaulD]

Originally posted by -=BOOMER=-
kinda boring stuff.

I suppose it beats going out and getting into trouble ..... and you will have something to show for it, an accomplishment to be proud of

[sparq]

Originally posted by ci5ic
Actually, I heard a really good idea recently, supposedly works really well for making molds like that. What you do is coat the surface you are molding with Vaseline. Then, you lay plastic-wrap on top of the vaseline so that it kindof sticks to the surface. Then, just fiberglass over it, and you don't even need to use fleece. The only drawback I can forsee is that cleaning up all that vaseling might be a little frustrating.

Uhhhh, have fun cleaning all that crap up. Why dont you just do what any NORMAL person would do and tape up the area you are working in to make sure nothing gets where it shouldnt be?

[ci5ic]

Just an idea man... don't take everything so seriously...

P.S. That's why I said:
"The only drawback I can forsee is that cleaning up all that vaseling might be a little frustrating."

[soul180]

don't use vaseline, go buy a can of bees wax, rub 3 layers on the area you want to fibreglass (spare tire area), once the wax dries, fibre glass the first few layers, let it dry, when it's done dryin, tap it with a rubber mallet, the wax will spereate from the metal and you'll be able to pull the box out. That's what i did for mine, worked amazingly

[-=BOOMER=-]

Ok well after 2 weeks of bondoing and sanding i think i finaly got it to the shape i want it to be.
I have painted it with one coat of sandable primer and sanded it down to smothness. Now i will be doing 2 coats of real primer and then on to the real paint.

Here are some pics at this stage.
the brown is the sandable primer.

When im done it will be panted black with a clearcoat.

[-=BOOMER=-]

Oh and here are some of it in the car.

[-=BOOMER=-]

Ok I just got done with the prepaint fitment. I had to trim a few factory parts to make it fit good and look good too.
I do this before paint so that i dont scratch the paint after its done.