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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Charlie118118
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Rich (Staff) - 5/23/2019 4:13:45 PM
Whilst I agree with Hanaldo's statement that "Epoxy tooling gelcoat is going to be an awful pattern coating, it is designed to be quite tough and will be hard to sand flat and polish." and knowing this is for a FS project, if you only had access to the Epoxy Gelcoat, you could in theory use it - it won't be as easy to flat back and polish up as Pattern Coat Primer and it'll take serious elbow grease to get it to a reasonable finish but if it is all you have access to, it 'could' be used as a substitute (albeit not an ideal one).

Brilliant

Thank you all I've got a much better understanding of this now, so my new plan is as follows:

Pattern:
- Finished sanded pattern is coated in pattern-coat primer, and then the high gloss if we want a really good surface finish
- Apply 6 coats of the easy-lease chemical release agent, followed by 2 coats of the mould release wax

Mould
- Cover in Uni-mould tooling gel coat 
- Then add the 100gsm CSM with the Uni-mould coupling coat
-Add structural 2 layers of 450gsm CSM with Uni-mould tooling resin

Once again really appreciate the help guys



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Charlie118118 - 6 Years Ago
Rich (Staff) - 6 Years Ago
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