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That is a great bit of lateral thinking. :cool:
Good luck, Paul. :) |
Thanks Paul, its taking its time but I have been working on the car for nearly twelve years so another week is nothing in the scheme of things... :)
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Bonnet continued..
While the board was in place I got under the car and drew round the profile of the bonnet ready for when I needed to cut it.
http://i652.photobucket.com/albums/u...t/IMAG1903.jpg http://i652.photobucket.com/albums/u...t/IMAG1904.jpg I have continued soaking the cloth and moving around the weights, reducing the weights until I thought there was manageable spring back. http://i652.photobucket.com/albums/u...t/IMAG1905.jpg http://i652.photobucket.com/albums/u...t/IMAG1906.jpg http://i652.photobucket.com/albums/u...t/IMAG1907.jpg http://i652.photobucket.com/albums/u...t/IMAG1908.jpg Then off with the board and ready to cut the profile. http://i652.photobucket.com/albums/u...t/IMAG1910.jpg During the night the board had dried and it had lost a lot of its shape so I cut the profile anyway http://i652.photobucket.com/albums/u...t/IMAG1912.jpg Then sanded the areas at he touch points to make it fit the hole. http://i652.photobucket.com/albums/u...t/IMAG1913.jpg http://i652.photobucket.com/albums/u...t/IMAG1914.jpg http://i652.photobucket.com/albums/u...g?t=1448638797 Once done I marked out the cut lines for the bulge cut around the lines and placed some spacers to lift the bulge. http://i652.photobucket.com/albums/u...t/IMAG1916.jpg http://i652.photobucket.com/albums/u...t/IMAG1917.jpg http://i652.photobucket.com/albums/u...t/IMAG1918.jpg Once cutting out the bulge lines the board has started to reshape itself to the wing profile, I am sure with a little bracing from the underside the required shape can be achieved, I am now toying with the idea of making the bulge vented….. more work there then, what do you guys think? |
Bonnet continued..
I have cut out 5 ribs and marled out the curvature across the car and cut the profile on each
http://i652.photobucket.com/albums/u...g?t=1448726730 Then the plug was marked out for the fixing positions then drilled and assembled http://i652.photobucket.com/albums/u...t/IMAG1920.jpg http://i652.photobucket.com/albums/u...t/IMAG1923.jpg When all attached the whole thing was placed onto the car and using brackets and blocks, it was set so the profile was at an equal height off the car http://i652.photobucket.com/albums/u...t/IMAG1921.jpg http://i652.photobucket.com/albums/u...t/IMAG1922.jpg After that I pulled the plug down onto the brackets and then from the underside I made brackets to lock the whole thing to the car, then a coat of primer to seal the MDF in readiness for shaping the sides and front of the bulge and once done I will put a small radius around the edges in readiness for the gel and glass. http://i652.photobucket.com/albums/u...t/IMAG1925.jpg http://i652.photobucket.com/albums/u...t/IMAG1926.jpg |
Brilliant work!!!!!!!
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Bonnet continued..
Now to deal with the gap at the front, first was to cut out a piece of ply to take the shape at the front
http://i652.photobucket.com/albums/u...t/IMAG1927.jpg Then the leading edge was sanded down to remove most of the step were the ply meets the MDF http://i652.photobucket.com/albums/u...t/IMAG1928.jpg Next was to fit the board, it was placed into position and wedged at the rear to maintain the shape at the top then screwed at the front to secure. http://i652.photobucket.com/albums/u...t/IMAG1929.jpg Next it was off to the shop to buy some modelling clay, this was applied over the board and around the edges to smooth out the required shape. http://i652.photobucket.com/albums/u...t/IMAG1931.jpg http://i652.photobucket.com/albums/u...t/IMAG1932.jpg http://i652.photobucket.com/albums/u...t/IMAG1933.jpg This was then left to cure over night……………………… total disaster in the morning the clay had shrunk something rotten and cracked all over the place leaving all that work a total mess so it was all removed ready for a re-think, mind you I wasn’t really happy with how it looked anyway so nothing really lost apart from more time. http://i652.photobucket.com/albums/u...t/IMAG1934.jpg I made up some fibreglass strips in readiness for my next cunning plan.. http://i652.photobucket.com/albums/u...t/IMAG1935.jpg A change of thought so as to add some shape into the bulge, I removed the board then cut it to form vents, hmm that may look better I thought so the next thing was back off to the shop. http://i652.photobucket.com/albums/u...t/IMAG1935.jpg http://i652.photobucket.com/albums/u...t/IMAG1937.jpg Arrived home now armed with plasticine, that won’t dry and shrink so back with shaping, I was going to shape the plasticine into what I liked and make it a bit smaller than required, cover it with cling film and glass over, then remove the plasticine, refit and bond in the glassed shape and apply P38 over to finish and sand to blend. Right off I went http://i652.photobucket.com/albums/u...t/IMAG1938.jpg http://i652.photobucket.com/albums/u...t/IMAG1939.jpg http://i652.photobucket.com/albums/u...t/IMAG1940.jpg http://i652.photobucket.com/albums/u...t/IMAG1941.jpg Hmm this if starting to look like a naff American muscle car, not the image I wanted so had to have a re-think. Ha I know, I have a intercooler scoop from a Suburu, I could incorporate that I thought, so I removed the plasticine and placed it onto the bonnet to see what I thought… http://i652.photobucket.com/albums/u...t/IMAG1942.jpg http://i652.photobucket.com/albums/u...t/IMAG1944.jpg That’s it.. it will keep the looks of an old English sports car, Aston Martin, Austin Healey sort of thing, so got the old grey matter working again and made a start… More MDF was required so back to the shop…. First cut to rough size and mark out the shape and lay in place, http://i652.photobucket.com/albums/u...t/IMAG1950.jpg Then mark out the underside of the front edge for feathering then sand the front edge down http://i652.photobucket.com/albums/u...t/IMAG1945.jpg http://i652.photobucket.com/albums/u...t/IMAG1948.jpg http://i652.photobucket.com/albums/u...t/IMAG1948.jpg The front edge was sanded down checking the profile at each line to check progress until about 2mm thickness of the front edge was left. |
Bonnet continued
Trial fit of front board and a quick look with the scoop, starting to take shape so I think this is the way to go….
http://i652.photobucket.com/albums/u...t/IMAG1950.jpg http://i652.photobucket.com/albums/u...t/IMAG1951.jpg Drilled some hole and countersinks then screwed into place in readiness for sanding back the front lip of the bulge http://i652.photobucket.com/albums/u...t/IMAG1952.jpg http://i652.photobucket.com/albums/u...t/IMAG1953.jpg http://i652.photobucket.com/albums/u...t/IMAG1954.jpg |
Love the way you are so willing to experiment to get the final bonnet shape you want. :cool:
Good luck, Paul. :) |
Thanks Paul, I would rather get it right where I can, otherwise it will annoy me forever, may as well build it how you want it I say, it's like having your heart set on a red sports car with black interior and ending up with a grey one with blue interior, not the same thing.....
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Bonnet continued
Next was to prep up for adding filler, I applied filler primer around where I was to fill to give a bond surface for the main filler and allowed to dry. When it had a good day to dry I then started to apply around the open areas in the bulge and over the fixings until enough filler was in position ready for the next stage.
http://i652.photobucket.com/albums/u...t/IMAG1956.jpg http://i652.photobucket.com/albums/u...t/IMAG1957.jpg http://i652.photobucket.com/albums/u...t/IMAG1958.jpg http://i652.photobucket.com/albums/u...t/IMAG1959.jpg http://i652.photobucket.com/albums/u...t/IMAG1960.jpg http://i652.photobucket.com/albums/u...t/IMAG1961.jpg http://i652.photobucket.com/albums/u...t/IMAG1965.jpg I left the filler to go off and started to rub it down into shape.. http://i652.photobucket.com/albums/u...t/IMAG1970.jpg http://i652.photobucket.com/albums/u...t/IMAG1971.jpg When enough was taken back to get the shape a coat of filler primer was sprayed over the filled areas, this shows the uniformity of the shape and imperfections.. http://i652.photobucket.com/albums/u...t/IMAG1972.jpg http://i652.photobucket.com/albums/u...t/IMAG1973.jpg http://i652.photobucket.com/albums/u...t/IMAG1974.jpg http://i652.photobucket.com/albums/u...t/IMAG1975.jpg Next when the primer has had a good time to cure I will go back over with filler to cover the areas I have missed and fill out where the shape is uneven… |
Bonnet continued
Now to sort out the imperfections, more filler applied where required
http://i652.photobucket.com/albums/u...t/IMAG1976.jpg Then rubbed back… http://i652.photobucket.com/albums/u...t/IMAG1977.jpg http://i652.photobucket.com/albums/u...t/IMAG1978.jpg Then another coat of filler primer…. http://i652.photobucket.com/albums/u...t/IMAG1980.jpg http://i652.photobucket.com/albums/u...t/IMAG1981.jpg http://i652.photobucket.com/albums/u...t/IMAG1982.jpg http://i652.photobucket.com/albums/u...t/IMAG1985.jpg http://i652.photobucket.com/albums/u...t/IMAG1986.jpg Just a few more times round I think and some pockets added to accept the scoop then it will be ready to seal, then for the mould to be made from it… |
Bonnet continued
Right , I hope all had a merry Christmas and received all the parts you require to finish your projects, I have sent the wife back to work and now I can continue with mine….
The scoop for the bonnet has protruding fixing points so I fettled out the plug to suit http://i652.photobucket.com/albums/u...t/IMAG2011.jpg Once completed I gave it a quick coat of satin black to find more imperfections and also sealing the bare MDF. http://i652.photobucket.com/albums/u...t/IMAG2012.jpg More filler required, so applied around areas to fill any imperfections, hmmm been here several times and getting quite fed up with chasing my tail, I have decided that any small problem areas that remain will be cleaned up from the mould, first I will only need to do some light rubbing down and second the gel coat will be more forgiving as the gel coat is a lot harder than the plug. http://i652.photobucket.com/albums/u...t/IMAG2015.jpg Final rubdown and repaint… mask around the car and plug supports and ready to go.. http://i652.photobucket.com/albums/u...t/IMAG2016.jpg Applied a liberal amount of mould release agent…. http://i652.photobucket.com/albums/u...t/IMAG2017.jpg Now to hope for the best, a covering of gel coat, I really hope it all releases after all this prep work…. http://i652.photobucket.com/albums/u...t/IMAG2019.jpg Now the waiting game for a good few hours and then for the glass…… |
Fingers crossed for you, it's looking good!
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Thanks Mr Jones, its always a worry that it won't break out of the plug, first sheet of glass on now and hopefully the edges stay put...
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Bonnet continued
Right the mould has all been glassed and support rails fitted….
http://i652.photobucket.com/albums/u...t/IMAG2021.jpg http://i652.photobucket.com/albums/u...t/IMAG2022.jpg Once cured the plug and mould was lowered to meet the car…… http://i652.photobucket.com/albums/u...t/IMAG2023.jpg http://i652.photobucket.com/albums/u...t/IMAG2024.jpg The profile looks good and then……. Aaaaarrrggghhhhh…. I need a break |
Bonnet continued
Right worse nightmare ever but needs to be tackled, the plug didn’t release from the mould, well after a rant and a day off I took in the job of trying to recover the mould with limited damage, I ripped off the supports and then scored the surface of the plug, then put some water in and hoped it would soak in and give me a chance.. http://i652.photobucket.com/albums/u...t/IMAG2025.jpg After an hour and a lot of scraping out the MDF I thought this is not working too well… http://i652.photobucket.com/albums/u...t/IMAG2026.jpg After another 2 hours I decided to try something else, scrape it out dry… http://i652.photobucket.com/albums/u...t/IMAG2027.jpg 2 hours later that got most of it out… http://i652.photobucket.com/albums/u...t/IMAG2029.jpg Now for the steamer….. http://i652.photobucket.com/albums/u...t/IMAG2030.jpg Another hour or so….. http://i652.photobucket.com/albums/u...t/IMAG2031.jpg And another… http://i652.photobucket.com/albums/u...t/IMAG2032.jpg Most of it out and now to think about the paint, into work tomorrow to ask my welder for the details of the paint stripping spray he has recently has had good results from…… No more messing with nitromors… |
Oh Noooooo! Sorry to hear of the pain you are going through - it looked so good too. Fingers crossed it can be salvaged.
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