Just a few comments.

1) I`ve concluded that a thick shell is better as it allows you to excert more force when parting the blunt from the mould, a flexible mould just cracks and breaks, also deforms so is no good to use.

2) Once mixed the gel coats reaction to adding the hardener is VERY vigorous and gets very very hot in large amounts, leave outside once finished with it as its a potential fire risk (Keep kids away also as it can spit a bit

3) Pre cut all your fibreglass matting into a series of usable sizes. You only have about 10 mins of working time with mixed fibreglass resin...about 300ml is usable in this time, no need to mix up more as it will set before you can use it.

4) buy elbow length latex/rubber gloves as the glass fibres get everywhere and are a *bleep* to get out of your skin.

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ST205

Yes, Yes and thrice Yes......

Nearly there....3/4 of the top mould completed. For the first time I get to see what the airflow paths are like and I must say "spot on"

The 3 sections of mould awaiting prep.....one is just that minute broken off the blunt so looks a bit rough but so far so good...the easiest bit left to do which should get finished today



the hardest part to get right...looking good, obviously needs finishing and cropping but the final result should be good



Unfortunately the blunt took a bit of damage, but its repaired now and waiting for the final section

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ST205

Two halves together



time to break out the wet n dry

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ST205

looking excellent so far Nial!

If your moulds are any good I might be able to get this made in carbon fibre.
How the deal normally works is if you want anything made in carbon you send the part in to be copied, you loose your original but get a free carbon replacement and we keep the moulds for furture items. Dorris

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Black CS 2771

Now there is a tempting offer.....will see how good it all turns out.....it might yet turn to a big ball of crap......not sure if what I produce is up to your usual standards...this is the first time I have ever done anything like this so its all a bit "rough"

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ST205

Fantatic job, Mate!

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Wolf_Tm
TM 250 enduro 2 stroke
GT-four ST205 Snowy White with selfmade 3SGTE v4.1 - [2.34kg/bhp DynoDynamics]
http://www.youtube.com/WolfTm250
http://www.facebook.com/wolf.tm

On this fantastic sunny day (in between wallpapering the bedroom and a bit of gardening) I managed to find time to make the final part of the male mould.



A bit of cleaning and polishing to come.

A final picture of the mould in its current state, the access hole needs cutting bigger and smoothing off so I dont cut myself any more.


Prep shouldnt take too long (I nope)

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ST205

OK.....a final test before I dive in.

This is the bit that clamps the filter into the bottom box.....its just out the mould so has rough edges, but as its only a test I didnt see the need to make a neat finish.



The next test will be in the carbon fibre rep fibreglass, but will have to wait until the weekend.

It was a right pain to break from the mould...lots more layers of mould release for the next attempt and some careful cutting of the sheet of carbon effect FG so its a perfect fit.

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ST205

Excellent work as always Nial

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Life is a *bleep*..............then you marry one

Great work Nial, on the thinking, build so far, sharing your info and taking the time and effort posting it all here to help others!

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Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
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Turbocharging - the replacement for displacement

Thanks although it will be on hold for a while as I`m being sent to Taiwan for 2 weeks on friday....a week off when I get back though so I will get it finished then

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ST205

No you won't, you'll be too busy applying ointment to the rash....