Door card moulding.


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Lewismotorsport
Lewismotorsport
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hi guys I've been tasked with door cards moulded to the shape to suit a door and rollcage has anyone any ideas other than high density polyurethane foam?
Interloper393
Interloper393
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Use old door card as a base
Warren (Staff)
Warren (Staff)
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Old door card cut and shut around the cage is the best route to go.  Some people like to keep the door card shape with the door bar "cross" cut into it, others go down the route of the bottom half of the door card being cut back and just flat.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant
Lewismotorsport
Lewismotorsport
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thank you warren, thats what im hoping, however what do you put into the door card in the shape of the cage  to get that semi circular shape into the door card? so like moulded shape so that we can take a mould from it all in one piece?
Interloper393
Interloper393
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Plastic pipe? 
Hanaldo
Hanaldo
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Plastic pipe would work, but if it were me I would cover the cage tube in 5mm sheet wax and splash a quick fibreglass half pipe off that, then you can fibreglass that into your door cards wherever it is needed. 

Reason being, I prefer to have solid plugs that can be prepped and painted properly before moulding. You can get away with having plastic or wax or clay or whatever works on your plug, but it won't give you as nice a finish on your mould and so you will be chasing your tail trying to fix it. Of course if this is purely for weight saving and you don't care about cosmetics at all then that doesn't matter, but I always prefer to have the best of both worlds. 
Interloper393
Interloper393
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Maybe pop a few pics up of what you have and aiming for Smile
Lewismotorsport
Lewismotorsport
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brill idea! this one wont be made to exact as the customer has messaged me now saying hes made a template, however im building my own fiesta 4x4 this would be beneficial for me there too.. i like a challenge and it has to be perfect.
GO

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