Greetings,

I'm looking to create a pattern by utilizing the existing bumpers and side skirts of my car and re-shaping them, or rather adding to them perhaps, quite considerably.

The below pictures will hopefully serve to give you a general idea of what I'd like to accomplish...

Standard front view


Modified front view


Standard rear view


Modified rear view


My main question is what material would I preferrably use in making the patterns? I'd like to be able to retain the use of the original bumpers and side skirts and thus need to be able to create the pattern without damaging the standard items.

I'm also curious of how to go about making the patterns are perfectly symmetric on both sides of the center line? Please keep in mind that I will be doing this myself without any access to CAD programmes or CNC machinery, I'll be doing it in my garage using only tools that can be bought online or at the local hardware store (within sensible price ranges).

I'm aware of the fact that this may seem an ambitious project for a beginner, but we all need to start somewhere. If these pieces end up well I'll also be considering building a custom interior for the project.

I'd be very grateful for any input!

Alecci of Sweden

1999 Maserati 3200 GT
1999 Nissan Skyline GTR

Hi and welcome. Nice project you have there If it where me I would start by laying up a simple GRP skin  (1-2mm thick)over the existing panels. If you use plenty of release agent you will not damage the original panels I would then cut,shape,alter those skins to the new shape/profile you want using foam, body filler etc. You can then either take moulds and reproduce in Carbon etc ( and have the ability to make and sell more) or simply finish and paint the modified skins. You will still have the the option to take moulds if there proves to be sufficient interest from other people.

I agree with Wozza.
No matter how hard you try you will wreck the existing panels. I would pull a fiberglass mold off of the existing part and then pull a part out of this mold to become the base for your changes. This would become your mockup for your final mold.
Fred

I agree with fred as well if you'r really willing to keep the original part intact, this is the best way!

Matthieu Libeert
Founder MAT2 Composites X Sports
website: www.mat2composites.com

Cheers for your advice, it's much appreciated.

In my own mind I had imagined the right way forward would be to cover the original part in some way - I've seen people using some kind of tape for this - and then add the material for the pattern, such as foam, clay or bonocell. After I have the shape I want, the next step would have been to make a mould using fibreglass or some other suitable material, and then finally creating the new part out of either carbon fibre or fibreglass.

If I follow you correctly, it's better to make a mould of the original part, then creating a new part from that mould and modifying that one, then another mould and only then the part? Seems a considerable deal of work, but if that's your verdict I'm not the one to question you. A positive side is that I'll hopefully learn something by creating the first mould which will aid me in the creation of the second one.

Whatever path I choose, what would be the most suitable material to use for making the pattern, and the mould as well I guess?

The other question still remains as well - how does one go about this making sure that the pattern is symmetrical on both side in relation to the center line using only hand tools? Measurements? Templates of some sort?

Once again, many thanks for your input.

Alecci of Sweden

1999 Maserati 3200 GT
1999 Nissan Skyline GTR

Templates and lots and lots of patience There is no quick way of achieving what you are trying to do unless you have access to CNC machinery and Digitizing equipment. As I said just make a GRP ( fibreglass ) skin of the original ( no real need to take a mould ) You can then alter, create the shape you require from that without damaging the originals. From the pictures you would be taking away as well as adding shapes, How can you do that using the originals without damaging / changing them? Work from the centre line, work on one side at a time. When you are happy with that use templates to replicate the shape on the other side. Be prepared for a lot of filling, sanding, filling, sanding and even more filling and sanding. If it was easy then everybody would be doing it 

I'm afraid I agree with the above method.  Skin mould, new part, modify part, remould.  I have a VX220 (opel speedster) and have done the same myself with a few panels.  It is A LOT of work but its all part of the fun.  The difficult part is being patient when you want to see the results of your efforts.  Put aside big blocks of time as you'll never do it in the odd hour here and there.  WRT making the additional parts, I have used the pattern board with good effect for this sort of thing but it isn't cheap.  YOu can draw on it which will help you get a nice symetrical part, you can bond to it if you take away too much, it really is a good material. 

Nice car by the way.  Always loved the boomerang rear lights on the 3200.  It was a big mistake by masser going for square ones on the later cars