Cosworth YB Turbo Into Elan

[stevebroad]

However, I was watching a video of an Australian guy making a mould for his race car and noticed that he brushed resin on to the pattern first then added DRY FG and brushed on resin afterwards. This was a lightbulb moment! SO much easier. I made the second part of the roof mould using this method - cleaner AND quicker

It has since transpired that this is the normal way to do it and even my son does it this way! Oh well, better late than never

I must say I do the dry cloth method onto a soaked base, however, watching 'Bitchin' rides' ,as you do in lockdown, they do it your old way 'because it's more effective at getting rid of the air bubbles'.
I guess it doesn't matter for a mould.

Good point. I have had to remove a lot of them.

[stevebroad]

This was my first use of my 200gm/m2 prepreg stuff. As it was being 'persuaded' to come out of the mould I was thinking, Oooooo, this seems too flimsy, maybe I have overstepped the mark and been just a layer too ambitious (only two layers). However, once out it seems pretty good and will stiffen up once married to the rest of the door. The curve adds a lot of tension stiffness so I think that it is a goer

Weight? 379gms I reckon I should be able to get the door very close to 1kg.

Mould wasn't glossy hence the dullness. No pinholes but a few defects that I didn't notice in the mould. However, these will fill easily and be covered with paint so no worries I added a couple of extra strips where the door latch button will be.

https://www.youtube.com/watch?v=-zcvWAK ... e=youtu.be

[stevebroad]

Showed my effort to my prepreg supplier's tech rep and discussed the merits of 3 layers of 200gms compared to one layer of 200 and one layer of 400 for the roof as I don't think two layers of 200gm will be enough. He replied:

"That door looks really good and the weight is perfect, a 1kg door is impressive. The dull finish actually makes it easier to paint – chasing a high gloss finish is actually something of a fallacy unless the part is on display with no laquer.

3 x 200gsm will actually give more stiffness than 1x 200 and 1x 400 gsm – although there’s not a huge amount in it"

Made me feel a whole lot better Onward and upward with attempting to remove the mould from the roof.

[stevebroad]

Tackled removing the roof mould this morning. I was expecting the usual sh1tfight but was pleasantly surprised. Took 45 minutes.

https://www.youtube.com/watch?v=de4m0ak ... e=youtu.be

[nmauduit]

Tackled removing the roof mould this morning. I was expecting the usual sh1tfight but was pleasantly surprised. Took 45 minutes.

https://www.youtube.com/watch?v=pfIVJ7a ... e=youtu.be

apparently the much awaited video is labelled as private ... would you check if the setting is public access? (pretty pliz...)

[stevebroad]

Tackled removing the roof mould this morning. I was expecting the usual sh1tfight but was pleasantly surprised. Took 45 minutes.

https://www.youtube.com/watch?v=pfIVJ7a ... e=youtu.be

apparently the much awaited video is labelled as private ... would you check if the setting is public access? (pretty pliz...)

Now, aren't I a tease? Ooops, apologies, didn't check the public box. There you go.

[stevebroad]

The eagle eyed, mould experienced guys amongst you will probably have noticed my schoolboy mistake. I was so worried that the mould would be a bitch to get off that I forgot about drilling holes for the attachment bolts used to join the two parts together. You drill these BEFORE you remove the mould to ensure that the two or more parts re-assemble correctly.

Wally of the first order. However, the saving grace is that, as the mould came off so cleanly, I was able to re-attach it to the roof and drill the holes. Phew!

[661]

You are very luck my doors have had hours of work on them ready for paint or I'd be on to you for a set.

[stevebroad]

You are very luck my doors have had hours of work on them ready for paint or I'd be on to you for a set.

Phew!

[nmauduit]

nice, thank you! it looks so quick n easy when other people do it... looking forward to see the molded part

[stevebroad]

nice, thank you! it looks so quick n easy when other people do it... looking forward to see the molded part

This came off SOOOO easily, which is not what usually happens. However, I did add a lot of release agent and added selotape between the two vertical flanges on the roof. Having edges that allowed me to slide in the knife also helped.

Cutting out the carbon parts for the rear of the driver's door at the moment. Once that is cooked I will attack the roof.

[661]

You are very luck my doors have had hours of work on them ready for paint or I'd be on to you for a set.

Phew!

You , Sir, are not off the hook yet. Keep the moulds!

[stevebroad]

You are very luck my doors have had hours of work on them ready for paint or I'd be on to you for a set.

Phew!

You , Sir, are not off the hook yet. Keep the moulds!

Unfortunately (or fortunately for me ) the doors were modified to fit my door openings so they aren't standard, whatever that was.

[stevebroad]

Sorting out the door carcus.

[stevebroad]

If I never see another Elan door mould it will a lifetime too early This door has 47 pieces (which include strengthening plates for hinges etc) and I have just laid up the first of two layers. Trying to stick carbon to a surface that is treated with release agent is no simple task when you have a lot of angles to contend with. Lots of heat gun action was required.