Talk Composites - The Forum for Advanced Composites

Need Help With Flanging This Complex Piece Pic inside

http://www.talkcomposites.com/Topic13145.aspx

By whitecel - 10/5/2014 5:38:35 AM

Hey guys,
  This may seem simple, but I've been baffled and frustrated in how I should tackle the ends of my door sill.  Short of using an enormous amount of fillet wax, how should I go about flinging the ends?  These are the two ends.  The only way I see it working is if I slowly cut and glue little by little to go around the curved edges.  Any help would be greatly appreciated.

Thanks in advance.

One side 


Other side
By wozza - 10/7/2014 5:42:47 PM

A method I use a lot for parts with open ends is expanding foam. Squirt some in each end, once cured trim/ sand to shape. Cover the foam in flash breaker tape or parcel tape and use filleting wax to fill the join line. Easy to work with and more substantial than card.
One thing to keep in mind with trim parts is that they often "relax" once removed from the car. You spend ages making a mould, then a nice shiny part to find that it actually no longer quite fits. The same is true when adding flanges, it is easy to change the shape or twist things slightly.
Warren