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780 air dam fabrication 700

posted by  c_j_mooney on  Sat Nov 5 17:37 CST 2005
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last visit: Wed Sep 14 17:39 CST 2011
[RELATED]

Well I've finally started a project that's been on the agenda for the last year - making a mold of a reasonably intact 780 air dam so I can produce a fibreglass replica of it. As of this evening I've completed a fibreglass shell that I laid over the existing dam, and the results are promising. I'll reinforce the shell by glassing wooden dowels or laths to the underside after building it up with another layer of glass mat. There's going to be a fair bit of work to get the lips and edges square and smooth, I figure I'll use bodyfill and 2-part spot putty for the finish work, then a nice smooth coat of acrylic enamel. If I get it right I should be able to replicate the air dams, relatively easily. I've used fibreglass rather than plaster for the mold, because its flexibility allows me to correct a nasty curve in the original from where it was already repaired.
Any thoughts? Advice? Suggestions?

Regards,
Chris
--
Chris, Dartmouth NS Canada 70 M-B 280SE, 83 245DL, 84 244 turbo, 90 780 turbo, 92 VW Golf, 90 740 Rex/Regina






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