Fiberglass and composite parts are commonly used in many collector cars, hot rods, Corvettes, and even late-model vehicles. Body panels, interior components, and engine parts are fabricated from fiberglass and composite materials (plastic molded or carbon fiber). While other fiberglass and composite material books have been published, few are focused on fabricating and repairing automotive parts, and this book concentrates on completing common and advanced projects at home in the garage.
The reader is shown how to use glass strand mat, woven fiberglass cloth, carbon fiber cloth, and hybrid fabrics for particular applications. The strength of these mats and ideal uses are covered in detail. Also shown is how to correctly mix the typical resins (polyester, epoxy), hardeners, and gels. Core materials, such as wood, foam, and honeycomb Nomex, are often used to add strength to various parts. All the relevant tools, including mixing containers, holding containers, saws, scissors, files, and shaping tools, are discussed. Constructing patterns to exacting standards from wood, Formica, aluminum, and other materials is essential and covered in detail.
TABLE OF CONTENTS:
Acknowledgments
About the Authors
Introduction
Chapter 1: Fiberglass Overview
- What is Fiberglass?
- What is a Composite?
- Choosing Your First Fiberglass Project
- Restoring Classic Fiberglass Cars
- Dune Buggies and Custom Fiberglass Cars
- Replicas and Kit Cars
- A Word about Boats and Planes
- How Does Fiberglass Work?
- Fiberglass Safety
Chapter 2: Safety Gear, Relevant Tools and Workshop
Safety Gear
- Fire Safety
- First-Aid Kit
- Personal Safety
- Fiberglassing Supplies
- Tools
- Hand Tools
- Electric Power Tools
- Using Air Tools
- Creating a Good Fiberglassing Workshop
Chapter 3: Fiberglass Cloth, Mats, Resins and Composite Materials
- Types of Fiberglass
- Fiberglass Resins and Catalysts
- Polyester Resins
- Epoxy Resins
- Casting Resins
- Project: Basic Fiberglass Layup
- Fiberglass Fillers, Pigments and Gel Coat
- Composite Materials
- Using Pre-Preg Carbon Fiber
Chapter 4: Basic and Advanced Repairs
- Reinforcing Your Repairs
- Cold Layup Composites
- Fiberglass and Composite Repair Projects
- Project: Making Simple Repairs to Gel Coat
- Project: Making Simple Crack Repairs to Fiberglass
- Project: Repair a Crack in a Corvette’s Bodywork
- Advanced Project: Fixing Holes in Fiberglass
- Advanced Project: Making Fiberglass Seam Repairs
- Making Repairs with HyperFiber
- Project: Reinforce and Repair with HyperFiber
Chapter 5: Pattern and Mold Making
- Patterns
- Bucks
- Molds
- Captive Forms
- Creating Fiberglass Molds
- Project: Create a Buck/Mold and Make Several Cobra Cockpit Wedges
- Project: Fabricate a Ford Model T Roadster Dashboard
Chapter 6: Professional Composite Operations
- Beginning with an Idea
- Creating the Buck
- Making the Mold
- Creating the Final Part
- Patterning the Carbon Fiber
- Matching the Carbon Fiber Weave
- Adding the Supporting Core
- Finishing the Layup
- Baking the Carbon Fiber
- Carbon Fiber Structural Parts & High-Stress Applications
- The Fabrication Process
- Testing the Parts
- Safety and Stress
Chapter 7: Plastics and Composite Vehicle Repair
- Vintage Plastic Cars
- Modern Plastic Cars
- Identifying Plastic Body Parts
- Repairing Plastic Parts with Fiberglass
- Project: Repair a Plastic Spoiler using Fiberglass
- Repairing Plastic Parts with Welding
- Types of Plastic Welding Rods
- Practice: Basic Plastic Welding Technique
- Plastic Tack Welding
- Practice: One-Sided Plastic Welds
- Practice: Two-Sided Welds
- Plastic Welder Maintenance
- Repairing Plastic Mounting Tabs
- Repairing Plastic Parts with Glue
- Project: Repair an Automotive Bumper
- Working with Sheet Plastic
- Project: Make a Set of Rally Mud Flaps out of HDPE
- Plastic Aerodynamic Devices
Chapter 8: Prepping and Painting Fiberglass and Composite Materials
- Equipment
- Airbrush
- Prep Work
- Gel Coat
- Paint
- Painting Carbon Fiber
Glossary
Source Guide
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