Making A Basic Fiberglass Mold for Carbon Fiber Infusion 

Pro tip: Before working with fiberglass, rub baby powder all over your body. It mostly prevents the glass from getting into your pores, and makes the whole job about 99% less miserable.

Hello Sir. I know it's been 3yrs since these series, but how great these instructional videos truly are. I'm just now going to try doing a wide body and front and rear bumper mods on my Ford explorer. I've learned SO much from you. Thank you !!!

Man you made that old paint shine like new !!! My God it looked great !

I found this highly educational. Thank you.

Very cool tip about putting the scale in a zip loc bag!

Nice work as always. Can’t wait to see the trunk and hood fitted with hardware.

These vids are making me want to change all my bodywork from steel to carbon fibre too!

I never cease to learn something 😊

Really liking your videos TSG! Cheers, Doug

Thank you for making these

Nice work...i send my love from Greece !!!!!!!!!!

You do things I never thought possible in a small one man garage. love the videos im learning a lot. Greetings from vancouver

Insanely helpful thanks

I think not applying a full wet coat of PVA is the key to avoiding runs. At the moment I'm using a water base PVA, thinned about 50/50, with a "Preval" aerosol sprayer. I do a couple light mist coats (dried via hot air gun), then a final heaver mist coat. The moisture from the heavier mist coat is absorbed by and spreads through the dried PVA, so after a few minutes the whole part looks like it had a full wet coat. (I'm a noob, but I've been making a lot of parts without any of them sticking...)

I'm from Australia and love the knowledge! I just wanted to say I'm surprised to see the same weight scale I use for my epoxy down here 😅

The coroplast is an interesting idea. For folks that are not familiar with it, Coroplast is a plastic replacement for corrugated cardboard. This is what the US Post Office uses in the place of cardboard boxes. In the old days Chavant clay was used as the flange making material. It is available on Amazon. I think I would probably use hard clay for the edges, but nothing softer than Medium. When it is warmed it will stick to the cleaned area. You would soften it and roll it like pie dough to about a 1/4 inch thick and stick it to the edge of the form. It can also be used as a dam to create an edge for an undercut area. It will then enable you to make a joining flange for the mold.

Great video. I'm going to try to make some carbon fiber panels for a 70roadrunner.

Amazing!! Thanks so much!!!

Very nice job. Have me some good ideas

This is awesome I can’t wait to do this for my car when I have some room to work😅

Good job

Great job making these!!!!!! I could not tell what you used to trim the glass off. The vibrator saws work great for that!! The vibrator blades wear quickly! A drimmel cutting blade can be used to cut mor teeth !

Another material you can use to attach wood to the mold or to add more bulk or thickness is polyester needle punched batting. This is one of the smooth materials that is used in quilts.

Great info thank you sir!

Hi Love your job, next time u make a glasfibre mold u can put a tire valve in the middle of the mold, then u are able to put some air presure betwen the layers when u wana loose it

You have such a great, professional level delivery as you narrate. FYI for cars Its better to learn to work with aluminum when doing light weight one offs. All FRP one off construction is horribly toxic and dubious, (old cans of resin, gell coat, spent molds, trimmings etc). You say that you are "not cheap anymore" If that's the case I would at the least invest in a Festool electric sanding system w/ vacuum. Air tool sanding FRP is absurdly outdated, sends glass fibers everywhere. Your shop is never going to be the same.

After adding the fiberglass cloth you use a liquid that looks pale green. This is before you add the chopped fiberglass mat. When you add the chopped fiberglass mat, the polyester resin is brown and then dries to a green color. But what pale green liquid/resin did you use for the fiberglass cloth ? Thank you for your work and videos, they are very informative and fantastic !

The PVA can probably go on even thinner. We use it at work (Rexco Part-All) and apply it with a sponge brush. The thinner the better. It dries very fast when it's thin, and if you try to overcoat, it risks peeling up the previous coat. All you need is enough to keep the gelcoat from sticking. Also, if you ever have a spot where you can't wash it, a piece of duct tape will stick to it and peel it off.

Nice video as always. Have you ever made a mold of a interior trim pieces? Specifically the backside of them? They have these little prongs that clips to the car and can't think of a way to make one.

Do you think Plastic dip can also be used before gelcoat ? Nice video btw , very helpfull for me.

normally one would take a sharp new blade utility knife to trim the flanges instead of any grinding at all.

Hello! I was wondering if you'd be able to make an updated video on making a mold? I know through the video you said you've learned some stuff, so I'm wondering if you've gotten more tips n advice you didn't know or share in this vid?

Cool project! I hope to do some similar projects on my rolling iron. I'm a V60 driver from Ontario(I know Volvo lost its touch). Thanks for these videos! Is your accent from Cape Breton?

Are you using waxed or unwaxed resin and gelcoat? Also, another great video, Thanks!

Really cool as always ! One Question - how many layers of glass fabrics are necessary in order to make a part ? Is there any minimum requirement ? Also thank you so much to share your videos with us ! I think it would take really a lot of time !

New video, yaaaaay.

I'm going to do this soon . How many gallons of Resin did this mold take ?

Algo rhythm

Couple questions: i just noticed that peel ply has a gsm rating too do you have to add more resin for that? And what size tips are you using on your hvlp gun, mine only has 1.4

Devilbiss starting line guns are great guns yes good price but not much different then my 600 devillbiss gun

What gel coat are you using? Do you have the name of it? Some are with wax and some with out

bruh it was a freak accident I had a big ol shard of fiber glass stuck in my throat for 5 days then I had to go inside my throat and grab it out sounds about as savage as it is, I thought it was a piece of chicken for 4 days lol

Is this mold Good for Autoclave about 375°F and 85psi ?

Where did you find your fiberglass veil?

Why did you decide to use carbon fiber as opposed to regular fiberglass?

Thing 1, you don't do both wax and pva...you do either or, Thing 2....never use gp resin for a mold, use a filled resin, Thing 3, the bracing is a huge mistake, that will post cure and print through, Thing 4, extentions have no 90 deg flanges. This will produce only a few parts, ok for a quick, not proper for higher run....but it is a start to learn from.

Uhhh.... do you want to adopt me? I'll help you with projects... :)

بعد شـُـكر الله ' شــــــكــــــراً لك ؛ : Thank you وأصل شُغلك المـُمتآز Keeep UUUPPP . Keeep Goooing . ' أُكرّر شُكري لك . Same process we use it in aircraft industry Very Very Excellent steps in this process . Good steps 👍👍👍 مـُـهـندّس صيآنّة طــآئــرآت مدنـيــّـة . ومـُفتش مُرآقبّة الجودّة QC inspector ARAB Engineer and Sr. Lead QC Inspector FAA, IA Inspector NDT/NDI Level II Inspector Jeddah Dhahran Al-Hijaz .