Molding a Car Body - Full Custom Garage: Sports Car Edition - S04 EP13 - Automotive Reality 

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@@fullcustomIan Perfect. Subbed thanks lots for all you share its appreciated and keep up the amazing work man. Have a great weekend!

We were asked to take a look at a right off TVR Griffith 500 front end smash , it was all there just masses of shattered fibreglass I was a panel beater and other lad was a painter the only experience I had was on electric milk floats and Matra Rancho back end smash in the late 70's , there was a little bonus project another wrecked TVR , the guy had bought 2 , a good and bad one with loads of panel severely damaged and or missing he wanted us to fix the better one and take a mould of the front end and bonnet for the other one , the painter said there was a guy in the next unit to us who made glassfibre septic tanks we could pick his brains , we popped around told him of our task , he was really willing to give us advice as he had started out building kit car bodies , he used rope impregnated with resin then laid glassfibre matting strips over the rope for strength , we got the mold stuck in a few places but came off not to back , after it was finished the guy put the other car on hold and we never saw him again thank god , not long after a mate of a lad who also was in our compound cousin came up from Manchester he worked at a luxury boat builders and told us about blowing the hulls out of the molds with compressed air , they had fitted airline ends into the mold , he said they go for a couple of hundred thousand to a couple of million £££££ , and they got to take them out on test runs very nice .

YUP! I worked at a fiberglass fabrication shop, too. The bread and butter there was large tanks, but there was also a set of molds for a kit car body that that had been made there in years past The most difficult thing to de-mold was the water tank for an airport fire truck. Made on a male mold opposite of what is seen in this video, the thing was at least 12 feet long, maybe 8 feet wide, and better than six feet deeo, with a lengthwise sump that went down between the tandem axle rear wheels of the truck chassis. To facilitate popping the part off the mold...the mold contained several shop-made things that looked like tire valves from a car. There was an air fitting on the threaded end of the 'tire valve' inside the mold and a hose leading out from under the mold. The 'tire end' of the tire valve opened into a 1/4" opening right in the mold surface that was covered by an adhesive paper circle around an inch in diameter applied just before waxing the mold. When it came time to pop the thing loose, a modded air nozzle was put up to the hose leading to where you wanted to start...and each 'paper dot' got a puff of air in turn. You could see the expanding bubbles between the part and mold. You'd go around a couple-three times making the bubbles bigger until they joined. At that point the part was free and they'd come in with a forklift and just lift it off! Very rarely were wedges needed! The little impressions from the dots were de-burred, but not much attention was paid to fixing them. Still fixing something like that in the gelcoat of a car body would be nothing but a dab of gelcoat before sanding for paint.

@@Bluswede I also did a stint in fibreglassing, at a factory in Sydney NSW where we made firetruck bodies, tanks and crew cabs. Another line was making the fronts and cab interiors for the intercity double decker trains. Truck Mudguards and other items. Some of the older guys were affected by Polyester Narcosis and were somewhat crazy, Safety gear really is important in the industry and at that factory in 1980 there was none of it.

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