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Model Specific Questions and Info => MK2 Golf/Jetta and Audi 5k => Topic started by: Iamvandemon on August 07, 2020, 10:49:31 pm
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For anyone interested in learning how not to do it...
I wanted to make a body panel to fill in the hole in the front of my car. I wanted to do a foam core fiberglass build. I did some quick research and determined (wrongly) that the foam I had would remain structurally sound when in contact with poly filler and resins..
So I went to work. First making a backing plate of cardboard and tape.
(https://i.ibb.co/1fRF4vX/tape1.jpg)
Then I filled up the empty place with the foam.
(https://i.ibb.co/PC1fjRX/foam-front.jpg)
Then carved and sanded to get the new panels shape.
(https://i.ibb.co/YRGvBPk/trimed-front-2.jpg)
I filled in the air bubble holes in the foam and fill out low areas.
After lots of Filling and sanding I got the panel to where I wanted it.
(https://i.ibb.co/Gcq6NMq/mudded-front.jpg)
So I removed it and shaved up the backside, taking care to maintain the mounting points. Then I got everything lined up again and drilled the fastener holes.
(https://i.ibb.co/MgJxYWf/mock-up-front.jpg)
I felt that now was the time to fiberglass the backside to give it some rigidity. Then I would do any final adjustments to the front and then fiberglass the front.
When I came back the next morning the panel looked like a potato chip as a result if its reaction with the resin. I was heartbroken, but I don't have time to redo it right now, so I decided to just make it work until I get some more time to try again with a better plan.
Lots more filler and shaping. Not as nice as the first time, but It will be close enough.. I made sure there will be no foam exposed to the resin and then I laid fiberglass on the face.
Lots of work and plenty of fail, but it will do the job for now...
(https://i.ibb.co/VNTjVWM/final-on-ground.jpg)
(https://i.ibb.co/QJtF0JN/final-on-ground-3.jpg)
I hope yours turns out better.