Small update.

Finished up the front brake install.

Stainless lines.





Cleaned and powdercoated the spindle caps.





Nothing major, but something to report. More to come.

Here's a composites update.


Since I was able to successfully produce a skin that appears to fit the door(s), I needed to make a separate part for the felt window strip to attach to on the inside lip of the door panel....

...So....another plug...




I only care about the "square" edge and the top edge. I molded these plugs directly off the glass panels I have shown previously. These will make more sense in a minute.


Made a mold from that..


Then...... I infused the carbon driver's door panel and some glass top flange pieces to start testing the fitment.

Lovely!

Here's the top flange piece, roughly trimmed.





Flange piece, tabbed in place. This inner edge is what the OEM window trim/felt attaches to.




It also helps hold the door panel in place.




Which brings me to fasteners........






Instead of messing with interior clips, that just break, I opted for a slightly different approach.




I enlarged four of the door panel clip holes to accept a 1/4-20 nut insert.

Insert vs OEM






Tested on Ol' Crappy.



The theory works. Awesome.

Time to drill some holes into fresh carbon.










I like.

nice


do you clear the carbon?

No, that's out of the mold finish.

They were made with UV resistant epoxy, so it is unnecessary for post production spraying.


If you spend enough time on the plug, making it "perfect", it insures you don't have to do much of anything to it after it pops. The better the surface of the plug, the better the surface finish of the mold, the closer to "Class A" finish you become.

These are pretty damn close to Class A.



For reference, each of the plugs for these panels required over 25 hours of fairing each.

This post was edited by OldAndyAndTheSea on Apr 28 2015 07:44pm

Are there different epoxys to give different finishes?

Maybe a sweat clear pearl or flake might be really cool over carbon, or really ugly... Never seen it tho

nice morror door panel