sly's BvS DOJ Build
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Posted 6/18/2020 1:13:16 PM


Supreme Being

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Last Login: Yesterday @ 11:48:35 AM
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Two layers of 1.5 oz fiberglass mat applied. Used an old garden hose to create strengthen the mold. Garden hose is only a form, it's the fiberglass around it that creates the strength.

Tomorrow I will sand down the mold a little to remove any stray pointy fiberglass threads that might sick someone handling the mold. Then I will drill bolt holes in the flanges between the top and two bottom sections so they can be bolted together when it's time to make the part.

After that it will finally be time to separate the mold from the plug and see what we've got! I'm very interested to see how the quarter inch fiberglass strands that were used in tight corners work. Could be key for the body construction.

Batmobile

Batmobile
Post #168611
Posted 6/18/2020 3:23:43 PM


Supreme Being

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Last Login: Yesterday @ 11:48:35 AM
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Went ahead and removed the flange plates from the front bottom and rear in preparation for smoothing out the flanges.

Batmobile

Batmobile

Batmobile
Post #168612
Posted 6/18/2020 5:41:40 PM
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Last Login: 8/4/2020 2:49:27 AM
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That thing is looking awesome
Post #168614
Posted 6/19/2020 3:06:39 PM


Supreme Being

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Thanks Towman. Not as cool as your build, but I'm trying.
Post #168615
Posted 6/19/2020 3:34:52 PM


Supreme Being

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Alright, here we go!

Trimmed up the flanges and did a light sand on the top to remove any stickers. Drilled the holes in the top to side flanges for bolts to hold the mold together when time to make a piece.

Batmobile

Started separating the passenger side bottom from the top section. Working from back to front and taking it easy, the bottom side mold section came off fairly easily and pretty clean.

Batmobile

Batmobile

Same thing with the driver side

Batmobile

Now for the top. It held on like a mother bear!

Batmobile

In retrospect, this was way too big a piece to do at one time. The lines, and other features on the surface were tough to get to release. If I had it to do over I would have divided it into three sections to help it separate better.

But eventually it came off. The plug got broken up a little but the mold looks pretty good.

Batmobile

Batmobile

Batmobile

Look how good the lines came out. I'm pretty stoked about that.

Batmobile

Batmobile

There was some heat melting of the foam but the layer of epoxy resin held it's shape so the melting didn't effect the mold.

Batmobile

Batmobile
Post #168616
Posted 6/23/2020 9:03:38 AM


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Last Login: 7/22/2020 7:50:18 AM
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Amazing stuff bud!!

David
Post #168622
Posted 6/30/2020 12:51:16 PM


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I have the body work done on the rear main body bottom now. Zeus Wayne suggested I try drywall mud again rather than body filler putty so I used it on most of this part (except for the parts I had already completed). I think there are pluses and minuses to both materials.

Body filler putty:

plus: strong bond, structural strength, easy to apply, cures quickly

minuses: expensive, LOTs of sanding, toxic, odor, harder to clean tools

Drywall Joint Compound:

plus: inexpensive, easy to apply, super easy to sand, easy clean up. no smell, safe to use indoors

minuses: takes a long time to dry, easy to over sand, can chip off and doesn't always adhere as well.

Here's the results. Gray parts are the body filler and white is the drywall.

Batmobile

Batmobile

Batmobile

I think I will continue to use the drywall for the most part as it is easier to use in the long run although not really much time savings because of the dry time. There are a few techniques to improve dry time and there is a product that is a fast drying mud that I may try.

Now I have to figure out how to put on the flange plates. there are some compound curves that I will need to divide into separate molds.

Post #168634
Posted 6/30/2020 8:55:52 PM
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hey sly,
Very nice work.
How are THEMAN and your donors coming along? vertigo
Post #168635
Posted 7/1/2020 7:39:51 AM


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Vert, nice to hear from you. Sure am missing your wonderful posts on this board.

How are THEMAN and your donors coming along?
Donor car is progressing. THEMAN has acquired the correct rear wheels, appropriate seats, and other items.

Talked to him yesterday and he had acquired a heavy duty transmission that we will need. I can't remember if he had the new rear axle sourced yet or not, but it was something we talked about last fall. I just sent him the donor seat rails because he wants to install the seats and start work on the roll cage.
Post #168636
Posted 7/2/2020 3:33:13 PM


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Last Login: 7/8/2020 8:26:29 AM
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Sly,

Yes a few minor disadvantages to mud, but the biggest advantage is no heat to warp or melt things...

Glad you are making progress!


Zeus
Bat-what?.....Na, it’s just an oversized badass black car (with optional machine guns)
Post #168638
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