Foam for fiberglass mockup

[mjpolifka]

I'm looking to make some custom fiberglass pieces for my car, but I wanted to start with a foam model to lay the glass on. Two questions:

1) is that the best way to do it?

2) does anyone know where I could get some foam? (online or brick and mortar, just fyi I'm near Chicago)

Thanks!

[iaminsider]

I will be watching this thread. I am very interested in this as well

[vettereddie]

How big are the pieces you're looking to do? If they're small, you can try Michael's, they're a crafts store. They have two types of suitable foam, one comes in 2" thick sheets and is very easy to shape. You can hot glue two or more together if you need it thicker. The other stuff they have is the brown foam used to stick artificial flowers in for table displays, etc. I'm using the white to try and make some half-wheel covers and a brake scoop.

If anyone knows what they use for larger stuff like body kits let me know too.

[Uncle_Unix]

http://www.uscomposites.com/foam.html

We use this for prototyping, anything above the 4 lb should be good. Of course the higher rating the better. Read the descriptions for your need

[ntwrkguru]

How big are the pieces you're looking to do? If they're small, you can try Michael's, they're a crafts store. They have two types of suitable foam, one comes in 2" thick sheets and is very easy to shape. You can hot glue two or more together if you need it thicker. The other stuff they have is the brown foam used to stick artificial flowers in for table displays, etc. I'm using the white to try and make some half-wheel covers and a brake scoop.

If anyone knows what they use for larger stuff like body kits let me know too.

It would seem that the stiff foam would be easier to shape, but do you treat it before laying the resin down? I'm wondering how it reacts to the resin. Or do you cover the foam with some sort of release material first?

I'll be following this thread as well. I have some FG projects planned for this winter.

[07Azuresciontc]

i have made fiberglass molds before u would cover the foam with green masking tape, the use 3m super 77 spray adhesive then lay aluminum foil over top of that, the masking tape allows you to pull the fiberglass off the mold, then just sand off the aluminum foil, hope this helps

[ntwrkguru]

Thanks!

[trinben]

some guys use expanding foam for larger pieces like body kits. for smaller pieces the easiest thing to use is flower foam brian mentioned. check out this site http://www.fiberglassforums.com it will answer any questions you might have :up:

[JDub86]

I just signed up on there, should have a lot of useful information.

[ntwrkguru]

Used the floral foam and t-shirt to make a rear-view mirror.... works like a champ!

[SpeakerBox]

Used the floral foam and t-shirt to make a rear-view mirror.... works like a champ!

Can you post or pm me some pics of that, I would love to see it!

[Inked06]

Ya, pics would be great. I can't wait to get into a house and have a garage again, lol I miss the smell of resin, bondo, and auto paint!!!!

[Aurora]

I too have a small project I'd like to try and do. I'll keep you guys posted. Is there such a thing as clear fiberglass? Like see through?

[07Azuresciontc]

you would have to use liquid acrylic i believe i have never worked with it so im not sure how it works

[Aurora]

Liquid acrylic....hmmm. Wonder if Michaels has that too.

[_Keith_]

some guys use expanding foam for larger pieces like body kits. for smaller pieces the easiest thing to use is flower foam brian mentioned. check out this site http://www.fiberglassforums.com it will answer any questions you might have :up:

Yep... closed cell foam is the type of foam to use...

[Aurora]

Closed Cell Foam? Yeah, I'm wanting to make a piece but want to do it the easiest way possible.

[_Keith_]

yep closed cell foam.. that way the resin doesnt eat it away.

[Aurora]

Hmm...but where do you get that at?

[Aurora]

Hey, how would you bend plexiglas? Like say you had to lay it on a curved surface, and you have a flat piece of plexiglas, how would you go about it?

[ntwrkguru]

Hmm...but where do you get that at?

Small pieces can be found at craft stores. Look for the floral foam. For larger sheets, you can get it from ebay.

[ntwrkguru]

Depends on the thickness of the plexi and the radius of the bend. Thin plexi will flex, but only in a single direction. Otherwise, you'll need to heat it up with a propane torch. If you wanna go that route, try to find an old piece to practice on first. Chances are you'll scorch it the first few times.

[Aurora]

Depends on the thickness of the plexi and the radius of the bend. Thin plexi will flex, but only in a single direction. Otherwise, you'll need to heat it up with a propane torch. If you wanna go that route, try to find an old piece to practice on first. Chances are you'll scorch it the first few times.

Would a heat gun work?

[Mark McKee]

I tried the foam way today the problem is there is 5 bends where im placing the piece. I was told the green foam will melt. So i was using the white foam going to wrap it in fleece. The first layer was to go on at perfect mix (hardener to resin) so call it a cold mix let it set up then place a slightly hotter layer on it after it dried. Im going to have to make a mold to do my project now. I hate to admit it but im getting my friend that is a fiberglass expert to help me do this. Ill take pics but the project probably wont be done for 3 to 5 weeks. I however was able to widdle the foam with a knife to shape it. I hope this helps out.

[Mark McKee]

I was told today by my buddy that after i make the molds out of fiberglass we will be usingexpandable foam to build up the pod then reshaping it and covering it in resin. Ill post up pics as the project goes.

[Aurora]

Hey Mark, I might need to get your help on my project piece as well. I'm actually going to attempt to do it in plexi first and see how that works. If it doesn't work, I'll have to go the foam route. I'll post pictures as I go. I just need to figure how how to bend plexi just a little. I know you can heat it but I don't want to burn the plexi (you know those burn marks from a flame).

[Mark McKee]

Yes ive heard of heatin up the plexi also. I have also considered if I knew of a physical therepist using the splint mold material that they heat up to make braces with. I was told to cover the door in pam then place aluminum foil over it and go. I want this done soon so im gonna do it myself the most reliable and affordable way. Plus its rewarding to be able to say you did it yourself.

[ntwrkguru]

Green floral foam doesn't melt. Pam isn't an ideal mold release agent. And to shape foam, I would use sandpaper.

My $.02...

[ntwrkguru]

Would a heat gun work?

Sorry I didn't notice this before. I've never tried a heat gun, but it may or may not work. Propane torches are pretty cheap.

[Aurora]

Yeah, but I have to hold this up to the body in order to get the curve right. Perhaps I should just do the foam route. Just that the plexi glass would be cheapest and it's just a mess around mod and if it looks good, then I'll go forward and make a really good fiberglass one....or maybe one of you guys can for me, lol.

[Mark McKee]

Made the mold yesterday out of fiberglass and pam worked on keeping glass off of door panel excellently. The aluminum foil peeled off of the resin without any problems. Ive decided we are going to use masonite(wood) attach it to the resin mold i made the glass it together.

[Aurora]

Hey Mark, are you going to post up pics? I'd like a kind of step by step for us that don't do this kind of stuff often.

ALSO, is there a way to make an item translucent?

[ntwrkguru]

Yeah, but I have to hold this up to the body in order to get the curve right. Perhaps I should just do the foam route. Just that the plexi glass would be cheapest and it's just a mess around mod and if it looks good, then I'll go forward and make a really good fiberglass one....or maybe one of you guys can for me, lol.

Are you trying to make a mold of the body? If so, just make it with FG to make a negative impression.


Hey Mark, are you going to post up pics? I'd like a kind of step by step for us that don't do this kind of stuff often.

ALSO, is there a way to make an item translucent?


What do you mean "item"? You want an FG piece to be translucent? Or plexi? FG will cure semi-transparent. If you want clear and not brown, you need to use the clear marine-grade resin, not the stuff from HD. If you want to frost that or plexi, then just sand it.

Also, what do you need a step by step for? Molds?

[Aurora]

PM'd...hehe

[Mark McKee]

ill post up pics im workin right now will be back on project sunday. The tweeter mounts i wont have beginning photos of but the 2 6.5 components i will. As far as making somethin thats clear Resin is brown I think you would have to go to an expert in plastic molding (expensive but the end result is worth it).

[ntwrkguru]

As far as making somethin thats clear Resin is brown I think you would have to go to an expert in plastic molding (expensive but the end result is worth it).

The stuff you get off the shelf is brown. You can order marine-grade resin that's clear.

[The_Butcher]

WoW. I'm glad I found this thread. I have had a hood mod idea that I've been wanting to do to my 08 xB for a while. I'm probably going to go the foam route..