Foam Molds
- Sheila Afros
How to Make a Foam Mold for Carbon Fiber (BMW Part 2 of 4)
Using a block of foam cut down to general shape then sanding (60 grit). Outside of the mold is then covered in spackling paste (Durabond 20 will also work). Apply PVA and wax as normal.
Ep 89: Carving a Foam Carbon Fiber Mold
Pink/XPS foam sand into needed shape. Foam is attached using hot glue. Coat in dry wall mud (even layer).
Making a Composite Part From A Foam Plug
Sand to shape then apply filler. Patent coat primer(1 coats). Then sand again (120 grit) to get rid of high spots). Low sports with body filler. Patent coat primer(1 coat). Sand again. 240 grit on last coat.
Applies high gloss finish (for high gloss finish). After cure finish with a 400 grit area. Move on to wet sanding with an 800 girt paper. Change water and use 1200. Change water and use 1500.
Polishing compound.
Gel coat. And apply fiber glass.
How to Make a Plug for a Mold - Part 3
Cut the foam into shape. Sand down to the shape that is desired. Apply 1 layer of fiber glass to the foam.
80 grit sanding the whole part (dig out excess air bubbles with knife). Extra sanding. Wipe down the part with acetone.
Fairing process. Putty system. Apply to mold (spreader). 2 layers and then let cure.
Rasp and 80grit to sand (to desired shape).
Epoxy primer to the mold (epoxy 505 2 layers). Then sand to 400 grit finish.
Wipe with acetone. Start building up wax (several times).