clubstylus

Last week the bracket which holds the endplate onto one of the air filters fell off (one of the cheaper unbranded chrome type ones - the spot welds had given up) and I've yet to get around to shelling out for another one so I decided to make some progress on the hood rail.

The plan is to make one up from the top of the screen, rather than trying to take a mould off Rob's one (for now, anyway) which from memory didn't look like it could be taken from a one-piece female mould though I could be wrong.

I reached that conclusion because my car has a push on rubber seal running up and over the rear edge of the screen. I don't know if any of the other cars have this seal but rather than faff about finding out I figured I'd just take a mould from the top of my screen with the seal in place and then it'd definitely fit, and if anyone else has the same seal, it'd fit theirs too.

So, out came the masking tape, stuck the seal down as tight as possible and covered everything in the stuff to avoid any nasty residue from the parcel tape which was laid down on top to provide a smooth surface to lay up onto. Resin won't stick to it, so it's a nice cheap solution.

Something like five layers of 450g/m2 biaxial glass and a good slop of vinylester resin. Then some rather crude bits of bamboo cane wrapped in parcel tape and clamped down with a bit more masking tape to consolidate then layup into the dip.

Just pulled it off and it's looking remarkably good for something of a rush job. Tomorrow when it's properly cured I'll make up the outer part over some kind of former. Haven't quite decided how best to tackle that yet. The whole lot will get stiffened up as needed with some inserts or another few layers of glass once the outer's done.

A bit more progress on the hood rail today. Basic shape's there now. Had to form the part that the hood stretches over using some cardboard from a frozen pizza box. Nothing like scrabbling around to find something you can bodge together for a last minute job The whole thing needs trimming correctly and filling/fairing to get it even and give more shape to the ends.

I think I'm probably going to use this as a plug to make a female mould from. I'll end up with a tidier rail and then the option's there to lay up a few more for anyone who wants one.

Well done Joe , you can always use mine to finalise the end shape

I've been referring to the photos you sent me, plus a bit of best judgment guesswork. I figured it didn't matter if it was slightly different from the original rail as it's the end of the hood which is most forgiving in fitment given that it just stretches over and is glued in place.

Progress is made slower by the fact I haven't got my angle grinder here... having to trim everything by hand...

The upright part of the rail needs to only just slope backwards away from the line of the screen , this helps keep the roof line higher away from your head

Totally haven't forgotten about this, just needed to pick up my angle grinder but it's been a busy few weeks. Looking at what I've made so far, I'll use it as a plug and vac-bag the rail over it. Hopefullt that'll fit over the screen surround nicely. It's a bit of a tight shape to get a reliable consolidation in the corners of a female mould I think.

Been a bit distracted by other stuff the past few months, but a bit of an update: My plug's not really any good as a male mould. Can only just separate it when it's loosely laid up over the plug, so if it was vac-bagged as it really needs to be it'd be impossible. So... I'll probably tidy up the plug and use it as is.

josephmoore wrote:Been a bit distracted by other stuff the past few months, but a bit of an update: My plug's not really any good as a male mould. Can only just separate it when it's loosely laid up over the plug, so if it was vac-bagged as it really needs to be it'd be impossible. So... I'll probably tidy up the plug and use it as is.

Unless of course you simply laid it up in single layer f/glass --- easier to prise off then lay up some more for strength on the inside once it's off

I suspect I'd need a somewhat more perfect plug than mine turned out. Once it's covered with the hood it'll hide the imperfections so I shan't worry too much. I think I'll have to take another look at your genuine rail some time, Rob. From memory it seems like a shape which would have to be moulded in two parts but i just can't see them spending that much time on a relatively small part.