Hey all,
Was hoping some of you may be able to offer me some advice on how to go about rebuilding a front splitter as a replacement for this:
The issue is, the bottom is obviously contoured but the top is flat. The whole thing is 25mm thick (overkill engineering wise, but it needs to be that thick now for the bodywork to fit). Now normally I would make 2 moulds, but I want to avoid this for 2 reasons:
1. Cost. It's a large part, and making a mould for both the top and the bottom is obviously twice the expense.
2. The box-section you see on top of the splitter is bonded on, and so I can't take a mould from it. Hence I would need to make a new plug, which again is more cost. I'm building this for a customer who is a friend of mine, so I'm trying to keep the costs down.
At the moment I'm leaning towards making a bottom mould and making a bottom section from that to have the shaped underside. Then, simply make a flat sandwich laminate using 25mm thick foam core. However this presents me with the issue of having to shape that flat sheet, and exposing the core, hence needing to do more finishing work.
Easier solution?