Moldless Car Body
Building a custom car body with fiberglass can be achieved without using a mold! This will be a truly custom, unique vehicle. It will take lots of planning and hands-on work, but is very possible as shown in these YouTube videos.
There of course are several ways to go about building a basic structure to use for the basic shape. This video gave lots of good ideas and examples of materials that are relatively inexpensive.
The second part of the video shows some of the actual fiberglass work. This video of less than eight minutes does not nearly do justice to the amount of work and effort that went into finishing this project! It was great that the author documented his work and shared with all. This was a major project that is not for the faint of heart.
He does a very good job explaining the process and materials used in this construction. Every project is unique, however. When discussing the thickness of the fiberglass skin, there are many variables that determine the finished strength. The number of layers to use is dependent on the amount of underlying support structures, part geometry, and required load bearing capacity of the structure. Some areas may need to be stronger for impact resistance and structural loads.
The video author discusses only using epoxy resin with Styrofoam as opposed to polyester resin which will react with the Styrofoam. Polyester resin can be used if separated from the Styrofoam with an additional layer. While I have only seen it advertised, there are new spray on primer materials available to cover the Styrofoam and allow polyester resins to be utilized afterward.
The Green Aspects of SMC
Sheet Molding Compound (SMC) is used to create many composite parts especially for the transportation industry, and contributes heavily to a positive environmental impact. SMC has been developed over the last 25 years to replace steel/sheet metal mostly in transportation applications. It is widely used in many heavy duty semi truck hoods, agricultural equipment, and pickup trucks, SUV’s and muscle cars.
The main goal of this substitution is to reduce weight, which improves fuel efficiency. Other positive side effects include fewer assembly operations, additional design freedom, dent and impact resistance, and the elimination of corrosion. Several “green” resin formulations have been introduced that make use of bio resins, which use much more renewable resources such as soy products. The fillers and reinforcements in this material can also be made from recycled and renewable materials.
SMC has overcome several hurdles in order to get to its present use and application. General acceptance and education had to be proven to the OEM manufacturers and consumers. Paint application and adhesion was one large consideration that had to be proven out. There were issues with popping and blistering from the SMC surface. Making sure the SMC parts held dimensions and aesthetics was also an important milestone.
SMC has become widely used today for many applications, and will find its way into many more. The weight saving aspects are paramount for reducing fuel consumption. The anti-corrosion and dent resistance are loved by consumers.
Sponsor
