Nissan Patrol 4x4 (Africa)

Cedric there are tricks to fibre glas not eating foam you paint it with wood glue first .....or cover it with gladwrap

Or dip it in liquid latex...

Cobra pollish also works great

Yeah I was looking for either something to dip it into. I like the wood glue idea.... that sounds like a very easy simple plan and will also give a smooth texture finish. I've never worked with the liquid latex, and think that that could also work well, depending on the price. Where does one get liquid latex and what does it cost. The other alternative would be to visit Builders Warehouse and check their specials table, as I've seen tins of Plasti-dip on the table for ( I think) about R150 per tin.

( thought to self..... ) I wonder if I dip the foam plug into bonding liquid type stuff I have at home....... It smells like wood glue and is basically a wall primer. I just cannot recall the product name at the moment. I know water based products and closed cell foam are probably not the materials that stick well to each other. I'll have to experiment with some off cuts when I get home.

Here are a few pics of the foam plug.....

The first 2 were to try give an eye line view of how it will look ( to see over the bonnet ) from the driver side, and the back seat driver (aka - passenger side )

For some weird reason i thought you were working in polystyrene...

Liquid latex: not sure but AMT or a.hobby (rc aircraft) shop should know if they don't have.

But with that foam, i would just give it a thick layer of wax (cobra or dubbin or similar).

AMT sells a wax called Ram.
I used this as a release agent on the weekend and it's excellent at that. I filled a 5mm gap between grp and an aluminium section and got no resin into the gap.

I like that idea !! I think it will also give the fibreglass a texture, even though I want to upholster mine. It will be VERY interesting to see the finish... I almost can't wait to wax on wax off....hahaha..... I might even call my dash console "the Brazillian"

Hey Cedric, I still have that GQ Clinometer for you!

Let me know when you'll be ready for it...

What does a tub of Ram wax sell for ?

I think we must get together soon JP !!!

Hey Cedric

I'm assuming you used a closed cell foam (eg. Sondor SPX60 ) to make your plug/mould ?
That foam is polyethylene based. Resin eats it pretty hectically.
It doesn't take any kind of filler material or wax well.
We've experimented with it in our pattern shop for tooling purposes.
The best way forward on that will be to clad the foam in a layer of tin foil (shiny side up).

Spread a thin layer of contact adhesive type glue over the foam and apply the tin foil while it is wet. Spread out any folds or blemishes in the foil like you were "ironing" it, so that you have an almost mirror type finish.
Once everything has dried, brush a thin layer of resin onto the tin foil until it is tacky.
Lay a layer of epoxy cloth on the resin and apply resin over the cloth to form a single layer of fibre glass.
Once it has dried, pop it free from the mould, give a light sand with coarse sand paper the inside and lay layers of cloth and resin to the inside to build your layers up for strength.

Hope this helps