Hi all.

I've been gathering bits and pieces for quite some time, and now just getting to put it all together.

68 bug, wrx engine/box, 18x10's and 8's, cage, seat....

The pan came from a hail damaged wreck from the Gold Coast about 10 years ago. Its a balljoint/irs. Had cookies on it at the time.
The body was bought a couple of years ago from a friend of mine.

I'll try and get the pics happening as quick as I can.

[img] http://www.cfab.com.au/G3/var/resizes/Customer-Galleries/Guru/A950.JPG?m=1294... [/img]

How do I get the bloody photo to show on this page?
I loose interest really quick with crap like this......

http://forums.aussieveedubbers.com/viewtopic.php?tid=21004 
http://forums.aussieveedubbers.com/viewtopic.php?tid=87954 
just two on the topic

get pics up fast, about time you started a thread on yours :TU:

Its been some time since I've added pics. I thought I was doing the same as before, but.....

If everyone is happy to look at small pics I'll keep going.

I made moulds for fibreglass guards years ago for a guy with a car he raced, so I pulled them out and knocked out a set.
They are 100mm wider than stock - they're huge - too wide really, but it gives me a rough idea of what I'm after.

Not all that happy with the shape so I've decided to make new moulds for the rears at 75mm wider than stock, and fronts that are around 35mm wider than stock.

Some nice handiwork in those fibreglass guards.

Righto - here we go.....

To make new moulds I need to make new 'plugs' for the new wide guards.
So I had to destroy 2 complete sets of good stock guards - 8 guards total -

As you can see the standard guard is a little narrow.

Don't take any notice of that motor either. Its not for this project.

Get the saw and start cutting.... its only metal.... its only more work.....

Set the 2nd guard over the 1st and screw it together. Lots of test fitting and measuring.

Stretch some parts and shorten others to make the guard flow and look 'original' then weld it up.
As the plugs are never going on a car for good, I didn't worry about fully welding them. No need to waste time and materials there.
Not looking too bad I think.

damn thats some wide guards. looks good though.

why not just run the metal guards? tiny pics but they look like they could work nicely..

You are very handing at making those guards and I can see a business opportunity to be selling a lot of fiberglass guards in the near future, if you want to go down that path.

Keep us up to date with any progress and well done.

Kev

STIDUB - a couple of reasons for not using the metal guards.
Firstly, they weigh too much and that stretches the bolt flange on the guard. And I would have to spend many hours stretching and shinking the entire guard so there would be alot less filler.
Secondly, if one gets damaged I can lay up another and its done. Alot of time goes into making one-off panels and to pay someone to do it, or spending that time again myself, well, it would just piss me off. 'glass is the way to go.

Ahhh thats how its done!

Thanks Brad. Lets see if I can get these pics big....

Next step is to smooth them out.



Then primer, and its rubbed back to an 800 grit finish.
I didn't bother with a top coat on these as the finished guard will be painted, not left as a gelcoat finish.

That's it - the plug is finished.

The guard has been bolted back on the car to give support to make the mould.



A coat of release agent is sprayed on and left to dry for around 20 minutes.



Next is tooling gelcoat which is sprayed and left to cure before the resin and matting is applied.





Guard is removed and th split flange is set up for moulding.
This makes the mould in 2 piece form which makes it easier to remove the product.

Nice to see a pro at work. Nice tooling up.

Very nice workmanship! I love the wide guards.

Nice work Guru... now you have the moulds are you going to make them to order?

If so how much for a set? (front and rear)

Thanks
Dave

good to see u on here mr brown

Nice job so far the guards look awesome and love the wheels you chose, just wondering how you went fitting 10"s on the rear. Did you use alloy 944 arms and then what wheels and offset did you use? cheers

Thanks for the comments guys.

JVL How are you, sir?

The front guard plugs and moulds are made the same way as the rears.










While I was working on the front I decided to mount the radiator and fit a vent to the front valance.
This piece is the windscreen cowl plenum vent from a Volvo.



The vent had to be shortened to fit.







And there we have it. Welded in, dressed and ready for filler and primer.

Here we see the front valance has been primed.

The front guards you see here are the 'plugs' for the moulds.
I painted these white to get some perspective of the shape when they're fitted to the car. Really hard to see the shape when they are in primer or painted in a flat finish.





I'm happy with the shape of the front plugs so I'll make the moulds then lay up a set. Should be good.

You have some skills guru. Fantastic work.

very nice mate....just let the rest of everyone know, ive purchase these guards...WORTH IT

Here's the finished mould for the left front guard.



While I have all the 'glassing gear out I thought I'd knock out a mould for these.






Eventually I hope to make kevlar and some carbon fibre panels with these moulds. Need a bit more equipment first and its not cheap!

From that last pic - is that a grey supra and a blue s14?
Could you indulge my ego and let me know?

Also, the car is looking GREAT!
Loving the front Mustache Grill

im also curious & guessing the same cars, curious whats in this shed