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?
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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. 
GO

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