Mould for car door

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Mould for car door

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Bluebull	Bluebull posted 12 Years Ago HOT Topic Details
Group: Forum Members Posts: 3, Visits: 17	Hey guys we started to brain about our first mold,.. a mold for a CFK door of a Mazda RX7 FD3S and we found a lot of tricky problems.. here are some pics of the door first step was to strip the door compleatly,.. after that we found some bad things,.. how would you do a mold for it ? we have no idea, because, you get no carbon in this small finn.. next problem,.. the shape of the window frame,... here is a sketch about the frame shape,... after more than a hour of brain storming this stuff become rudimentary :/ here a brain storm sheet ^^ we cut out the door frame... not really cut,.. we drilled the welding spots and removed the adhesive between all metal sheets without deforming any part... OK now we have the inner and outer side of the door,.. thats an easy mold,.. but the frame is tricky ! we want to use a (I dont know the englisch word for it, maybe its the same like in german - a lost core?) out of polystyrol foam ? and we change the shape of this frame... what is the best solution to get this polystyrol core? first an RTV positive mold, then a negativ mold and out of this mold the cores we need? why diddn't we start with a small piece ? or some easy stuff lika a bonnet :/ ok now I was drwaing about 1.5h on this stuff ... good night Edited 12 Years Ago by Bluebull
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FLD	FLD posted 12 Years Ago HOT Post Details
Group: Forum Members Posts: 468, Visits: 2.7K	Just my thoughts on seeing your project. 1) Why not make a carbon door and then bond in the OE steel frame? Yes it will be slightly heavier but it will be a lot less fragile. 2)If you want to make the frame in carbon why dissolve out the foam on your new design? Make it in PU or PVC foam and use that as a rigid core. The foam is light so the amount of weight you'll save is negligible and the strength it will add makes it worth keeping.
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