Upgrading your vehicle with a new tire and wheel setup can sometimes lead to unexpected issues, especially in racing scenarios. One common problem is tire rub against the bodywork, particularly the fenders, when the suspension compresses. A quick, albeit less than ideal, fix might involve cutting and bolting plates to create clearance. However, this often results in an unaesthetic and aerodynamically inefficient modification. For car enthusiasts and racers looking for a more professional and effective solution, modifying fenders with Fiberglass Car Parts offers a superior alternative to achieve both functionality and a clean look. This guide will walk you through a method to modify existing bodywork by grafting on new fender parts made from fiberglass.
Creating a Foam Mold for Fiberglass Modification
The first step in crafting your custom fiberglass car parts is creating a mold. Start by determining the desired fender line adjustment needed for adequate tire clearance. Cut a template based on this measurement, which will guide the foam cutting process. Blue foam is an excellent material for mold creation due to its workability. Using a hot wire cutter, carefully shape the blue foam according to your template. Position the cut foam on top of the existing fender to ensure it matches the intended modification and fits seamlessly.
Once you are satisfied with the foam’s shape and fit, secure it to the fender using clear packing tape. This tape serves as a crucial barrier, preventing the polyester resin used in fiberglass work from dissolving the foam during application. For added customization, consider incorporating design elements like vents. These can be fashioned from wood molding and hot-glued onto the taped foam mold, allowing you to integrate aesthetic details into your fiberglass car parts.
To ensure clean separation of the fiberglass mold from the foam, apply a generous coating of mold release wax over the taped foam surface. This step is vital for a smooth demolding process and preserving the integrity of your newly formed fiberglass part.
Applying Fiberglass and Creating the Mold
With the mold prepared, it’s time to apply the fiberglass. Begin by wetting fiberglass cloth with polyester resin. For this application, either woven fiberglass cloth or chopped strand mat (CSM) can be used. Note that CSM requires polyester resin, as epoxy resin will not properly dissolve the styrene binder in CSM. When working with woven cloth, a helpful technique is to pre-cut the cloth and lightly adhere it to your pattern using 3M Super77 spray adhesive. Then, using a short-bristled paintbrush, saturate the cloth with resin. If applying fiberglass in sections, ensure a minimum overlap of one inch between sections for structural integrity of your fiberglass car parts.
Allow the resin to fully cure. Once hardened, carefully detach the fiberglass mold from the foam pattern. You now have a negative mold ready for creating a positive part, potentially in carbon fiber for enhanced strength and aesthetics.
Molding Carbon Fiber Positives (Optional)
To take your modification a step further and create lightweight yet strong fiberglass car parts with a carbon fiber finish, you can mold a carbon fiber positive from the fiberglass mold. First, apply mold release wax to the inner surface of the fiberglass mold.
Next, begin layering carbon cloth inside the fiberglass mold, wetting each layer with epoxy resin. Use a short-bristled brush and a stippling motion to ensure the resin thoroughly penetrates the carbon fabric as it conforms to the mold. Epoxy resin is recommended for carbon fiber lamination due to the superior stiffness it provides to the final product, enhancing the performance of your fiberglass car parts.
For optimal strength, apply layers of carbon cloth in alternating 45/90-degree orientations. Woven carbon fiber is directional in stiffness, and this cross-ply technique maximizes rigidity in multiple directions. Before the resin completely hardens, trim any excess material around the mold edges with scissors. This is much easier to do at this stage than after full curing.
Once the resin is fully cured, the finished carbon fiber part can be removed from the mold.
Bonding and Finishing Your Fiberglass Car Parts
The final steps involve integrating your new fiberglass car parts with the existing bodywork. Bond the newly molded sections onto the car body using appropriate adhesives for fiberglass and automotive materials. To achieve a seamless and professional finish, blend the grafted parts into the existing bodywork using body filler as needed. With careful sanding and painting, your modified fenders will not only provide the necessary tire clearance but also enhance the overall appearance of your vehicle, showcasing the versatility and customizability of fiberglass car parts.
By following these steps, you can effectively modify your car’s fenders using fiberglass and carbon fiber techniques, achieving both functional improvements and aesthetic enhancements for your automotive projects.
