R32 custom diffuser


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PoRsCh3fReAk
PoRsCh3fReAk
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Hello everyone, my name is Alex,  i am a newbie to this mold and plug making game. Its been brain aching looking at all of these chemicals and processes that i feel everyone has and does differently. I have a MKV VW R32 and i am taking the plane jane exhaust surround and making it DTM styled. I've already added the fins and coated the whole unit in fiberglass. The product is smoothed over and i'm looking for assistance in my next step. I want to make a mould of this unit and that i can use to make a few one off carbon fiber duplicates. I will be honest i have a few bubbles from the fiberglassing and they need correcting.

My question is, can i use a filler to smooth the whole plug over and fill in some of my voids?Blink If yes what type of fillers? should i use Bondo which i've been seeing is "acceptable"?  Blink

If i use Bondo to smooth the piece, do i need to put resin back over it? Or, do i just primer over the filler and polish and sand that smooth to then start on making my mold.

I want this to be perfect and not have wasted a few months of work trying to learn everything I have. Any information AT ALLLL is greatly appreciates. I'm new to the fiberglass world and from what i've seen with forums this seems to have some good help and creative people.



_Alex

BTW this is where my bumper sits at the moment.
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wozza
wozza
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PoRsCh3fReAk (13/04/2014)
So after my filler and 2k application. I will then polish the 2k after it is all smooth. The shine should be as glass like as possible im assuming, then i will need to wax and apply mold release agent correct? 

I'm also on the search for the right mold making materials. from what i have gathered, i will get the plug ready with mold release wax and make sure all my corners will not get locked in the process. 

Next i will put on a coat of Gel coat? and when its tacky to the touch i will cover the back in layers of fiberglass to strengthen the back. And after its completely dry pop it off polish it and then make my product, correcT??

Also what brand items do you use?

2k primer
-polish to sine
-mold release wax - should i use this a few times over, ive heard multiple layers of wax or mold release to ensure remval of mold.
-put on a tooling gel coat
-strengthen with fiber glass.


If you finish the plug in 2k and polish it to a high gloss then you can use a chemical release agent like Easy-Lease. With PVA you will have to flat and polish the mould back to a gloss before pulling parts. It is much easier to work on the male plug than a female mould especially if there are recessed areas like the narrow fins on your diffuser. If your using 2k then after the high build apply a few coats of black 2k direct gloss. The black will show up any scratches far better than the grey high build. That way you can polish the plug to a glass like finish.
If you mould off that using a chemical release agent you wont have to do any work on the mould before use. Tooling gelcoat cures hard and is much harder to polish than 2k.
If you use a epoxy compatible moulding system like Uni-Mould then again you can use a chemical release agent on the mould instead of PVA so the finished part will only need a quick buff to remove any release agent residue. With PVA you will have to spend time flatting and polishing to a high gloss. When flatting cf parts you always run the risk of breaking through to the cloth effectively ruining the part. For me the less work you have to do on the part the better, spend the time on the plug and the mould.

Warren

Carbon Copies Ltd
GO

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