How to Make Fiberglass Parts with the Bare Minimum Tools.

Summary

This video tutorial demonstrates how to create a simple fiberglass lip spoiler using basic tools like a chip brush, fiberglass matt, gelcoat, and polyester resin. The process involves preparing the mould, applying gelcoat, layering fiberglass with resin, and ensuring proper curing. The video also covers techniques to avoid common issues like air bubbles and wrinkling. Additionally, safety precautions are emphasized, including the use of a respirator. The final steps include sanding, trimming, and adding logos before finishing the part. With a clear, step-by-step guide, the video is perfect for DIY enthusiasts looking to create their own fiberglass parts.

Takeaways

• 😀 Start with the right tools: chip brush, fiberglass mat, gelcoat, polyester resin, and mould release wax.
• 😀 Ensure the mould is clean and properly seasoned with a layer of wax before beginning the fiberglass process.
• 😀 Apply gelcoat carefully to create a protective outer layer, ensuring even thickness to avoid issues like wrinkling.
• 😀 Always mix the MEKP catalyst thoroughly (1.5%-2%) to ensure proper curing of the gelcoat and resin.
• 😀 Use proper safety gear, including a respirator, to protect against harmful fumes and dust during sanding and cutting.
• 😀 Avoid overlapping fiberglass edges to prevent thick spots and potential structural issues, instead feathering the edges for a smoother finish.
• 😀 The first layer of fiberglass is crucial for eliminating air bubbles and ensuring a solid bond with the gelcoat.
• 😀 When air bubbles appear, use gentle pressure or tools like skewers to release them, ensuring a smooth surface.
• 😀 Apply multiple layers of fiberglass (3 layers of 225 GSM in this case) for strength, especially in curved parts like a lip spoiler.
• 😀 After curing, ensure the part is completely hardened before removing it from the mould to prevent warping or poor fitment.

Q & A

What are the basic materials needed for making a fiberglass lip spoiler?

You will need a chip brush, fiberglass mat (225 gsm), gelcoat, polyester resin, MEKP catalyst, mould release wax, and optionally PVA for the mould.

Why is it important to apply a release agent to the mould?

Applying a release agent, like mould release wax or PVA, ensures that the fiberglass part can be easily removed from the mould without damaging either the part or the mould.

What is the purpose of using gelcoat in the fiberglassing process?

Gelcoat acts as a protective barrier between the fiberglass and the outer surface, giving a smoother finish and making sanding easier, while also preventing issues like wrinkling or alligatoring.

How do you ensure the gelcoat cures properly?

To ensure the gelcoat cures properly, apply it evenly and avoid areas that are too thin. If necessary, apply a second layer after 30 minutes to correct any thin spots.

What are common mistakes to avoid when applying the gelcoat?

Common mistakes include applying gelcoat too thinly, which can cause wrinkling or ‘alligatoring,’ or applying resin to uncured gelcoat, which can also lead to improper curing.

What is the significance of mixing the MEKP catalyst thoroughly?

Thoroughly mixing the MEKP catalyst is crucial because uneven mixing can cause improper curing, which can affect the final strength and appearance of the fiberglass part.

Why is it important to avoid lapping cut edges when laying fiberglass?

Lapping cut edges creates a thicker section in the middle, which can cause warping and structural issues, as well as an unattractive finish. Feathering the edges helps maintain uniform thickness.

How can air bubbles be removed during fiberglass layup?

Air bubbles can be removed by gently pressing or using tools like a skewer or toothpick to release the trapped air. Pushing the fiberglass can also help release tension and air bubbles.

What should you do if air bubbles appear after curing the first fiberglass layer?

If air bubbles appear, you can use a die grinder to remove the fiberglass in those areas and fill the bubbles with another layer of fiberglass.

Why is it recommended to use a grinder instead of a jigsaw when cutting fiberglass?

A grinder provides a cleaner, smoother cut without chipping the gelcoat, whereas a jigsaw can cause rough cuts and scratches. Grinders also give more control during cutting.

What are the advantages of using black dye in the resin?

Adding black dye to the resin gives a more aesthetically pleasing color compared to the pale straw color that resin typically turns, and it doesn't affect the structural properties of the resin.