Molding Cyclops panels

[jstewart]

I finally got around to taking the 2082 nose and side panels off. Currently studying how to remake it in fiberglass. I'm going to build a form to layer it into, using expanding foam. By covering it with Saran wrap, I hope to be able to use it more than once. The nose will be first and most likely the hardest to do. I will, of course be taking liberties with how it was made originally to attempt a more durable end result.

 

[jstewart]

Started attempting to make the mold yesterday, first attempt wasn't very good..................trying a different approach and it shows promise. Foaming a small area seems to work best. Giving the foam some small resistance as it expands seems to help. Trying to do the whole thing in one application opens the door to some hydraulic pressure and pushing out and hard to control.

 

[jstewart]

I'm going a different way than foam, it isn't holding dimensions very well. I've got something else in mind, that could be durable enough to make more than one grill.

 

[PACub100]

I'm keeping tabs on this one... My brother suggested that we do this since the panels on the 1864 are in very good shape.

 

[mstewart]

I hung around a boat builder in the 70s and he would build his mold out of fiberglass and then spray something called gel-coat on the inside of the mold before spraying the fiberglass and creating the boat hull......
I'm sure technology has bypassed that process nowadays.

 

[jstewart]

I'm looking at using lightweight concrete now as a mold. The shape of the nose looks to be easy to get to release from the mold, so several applications of wax should make it easy to get out and hopefully be able to re-use the mold. If not, I won't be losing much.

 

[jstewart]

I should have added that the crap mounting system molded into the originals will be left off. Too prone to breakage and should have been made out of 10 gauge steel......................will make molding much easier