Foam Plug and Mould creation


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Charlie118118
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Hi
Im currently making a large foam mould for uses as a nose cone for a small single seat racing car.  

We have used Easy Composites Low Density polyurethane foam to fill in gaps between our MDF skeletal frame.
I would like to make sure that I have the process correct for creating the mould as I only have one shot at this.

For the Plug once sanded body filled and completely finished i'll paint on a layer of EG60 Epoxy tooling gelcoat and allow this to fully cure, then apply at least 6 layers of the Easy-Lease Chemical release agent, followed by at least 2 layers of mirror glaze mould release wax. 

Then im using 4 layers of 100gsm CSM fibre glass to create the mould from which I can infuse upon.

Is this process correct or is there anywhere I should make alterations please let me know.

Thanks
Charlie




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Warren (Staff)
Warren (Staff)
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As Hanaldo says, you don't want tooling gel on a pattern.  The Pattern-Coat Primer is ideal for this job. Its easy to apply, easy to sand and shape and can be polished to a reasonable mid gloss if you want to skip the High-Gloss stage. 

Once your pattern is release coated and ready, the Uni-Mould system is ideal for making your mould.  Follow the mould making process in this Bonnet project video:  



As Rich says, you need a good lay up to make a strong enough mould of that size. The lay up in the video suits most cases and you can add strengthening ribs at the end as well to stiffen it up even more.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant
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