Learning fiberglass:
With the new bash bar built, I need a custom bumper cover. The original is rough but useable, however a buddy of mine would like it for the low budget father/son build he is doing. Replacement fiberglass covers are $200-300 and could not really afford that just to cut up.
Another friend told me about a technique of using masking tape on the original part to make a one-off. He said he had good luck with it, but had never done anything that big. The only FG experience I have is reinforcing my dash pad, but that didn't need to be pretty. I however am never against learning new things.... or taking things too far.
I used several layers of masking tape to cover the original cover, and made a separation in the middle, figuring the complex shape would give me trouble
Next I started laying strips of mat and resin. They say you should soak the mat with resin before application... and they are right! The process goes so much smoother that way.
After about 3-4 layers of glass it was looking pretty good...
The matting flange how ever was not great, as glass did not want to make that bend. But, I figured I could work that out.
The plan was to pop off the thin casting, remove the remains of masking tape and then build up the back side with more glass to keep close to the original part size.
And as predicted the shape, and size made it difficult to remove the casting, especially being as thin as it was. I Broke it in several places but it finally came off... but hey, its only fiberglass right?
I made a small casting of the center section and glued the two halves together. I then fitted it to the car and trimmed around the bash bar. I didn't want to put any more work in until I knew it was going to fit.
It's not great but I think I can make it work with more 'glass and sanding.
I think it really ties in the front bar visually... however I need to re-angle the flat bar the LEDs mount to, to match the nose angle. Apparently my measuring to a part that didn't exist, was not as accurate as it could have been
It would have been a lot easier to cut up my original... but I hate to do that when my friend can use it. It also would have been easier to cut up a new one, but I figure I will have about $100 in this one and a WHOLE lot of experience, I think that is better.