Mesh Grille Mod

[MH3.0R]

Ok, back on topic.

While the weather was nice this weekend, I did some prep leading up to the finished grille. This weekend was the fibreglassing (as recommended by cruisn). Temps were just above 15 degrees C on Saturday and about 18 degrees C today. As I basically started with nothing, shopping list cost $116.00 from Autobarn.



Saturday morning was prep. 80 grit paper to all the surfaces where the resin was to be applied.







Saturday afternoon (during the 2nd quarter as I though it was gonna be a thrashing) was the 1st section of glassing:







I only use two layers of fibre mat, which was probably a mistake as it turns to jelly once the resin mix is applied. It separates very easily when wet, so had to massage by hand a bit to get it where I wanted it.

On Sunday, weather in the arvo was perfect, 18 degrees C, no wind, and everyone else busy in the garden, so I did the other two sections in one session. This time I used 3 layers of fibre mat (as recommended on the kit), mixed a single batch of 40 ml resin and 24 drops of MEKP catalyst, stirred like crazy for 1 minute and started to apply the resin mix to all the surfaces that were prepared earlier and to all layers of the fibre mat. Again, when wet, the fibre turns fragile and separates easily, but managed to get the stuff into the grille where I wanted it.







Far from a pro job (this was my first time, a virgin glasser!). What I did notice as it was setting was the slight sag in the two sections that I had done today. Concerned that when I apply the body filler, that I will be sanding it back to the fibre mat as the sag is toward the surface line of finish.

Anyway, that is all for this weekend. Next weekend, I will attach the Body Filler, Spray Putty and Painting. I am also a Body Filler virgin, so do not have high expectations!

[castek]

Looking good mark, definately will be better than what is on it at the moment!

I did lie in my last post (cruisn marks thread) I DID fibreglass, i just forgot that i did it

What the fibreglass doesnt fill, will be covered up by the bog. Just as long as you take the time to get the finish perfect it'll come up great!!

I've got to get of my lazy ass and fix mine. It's pretty rough

[MH3.0R]

I will be looking at all the "pro" finish jobs during the cruise, so bring out your custom grilles for an impromptu award!

Maybe, we can have a show and shine at the start?

[rickerty]

looks awesome. I must admit I really liked the chrome surround.
Look forward to seeing the finished product, good work Mark

[Sentinel]

Looking good Mark. Sorry I couldn't join you to do this together last weekend mate.

On the upside, best way to confirm learning is to teach... Guess you'll be doin that with me soon then! LOL.

Catch ya soon.

[MH3.0R]

On the upside, best way to confirm learning is to teach... Guess you'll be doin that with me soon then! LOL.

Blind leading the blind!!! We need Cruisn to teach us both!

[MH3.0R]

Ok, Nice weather on Saturday, grand final a bi boring, so to the shed!!!!

First, a bit of prep, 100 grit sandpaper to go over the loose ends of the fibreglass and generally all the areas that I intend to use the body filler. Also, needed to trim the overlapping fibreglass, back to the natural lines of the grille. Tools of the day were:



Next, I mixed the body filler at exactly the ratio on the pack (50:1). Slight problem for quantities under 100g as the kitchen scales I have at my disposal (thanks luv ) can only weigh in increments of 2g, so I had to mix 100g. Too much for what I had to do. C'est la vie.

Anyway the stuff goes off very quick, like 8 minutes after mixing. So I spent 1 minute mixing (nice consistent colour) and 5 minutes filling. By the time I put the grille down and got some newspaper to empty out my mixing bowl, the residual had set like concrete! When they say 8 minutes, they really mean it! Do make sure that you have absolutely, all things at your fingertips BEFORE you mix.

So the results are:









As today is also a nice day, will sand then back, mask up the chrome bits and apply some coats of spray putty, sand, spray, sand, etc.

[Sentinel]

Looking good Mark.

[MH3.0R]

I do be luving daylight saving! I got home and there was enough daylight/time/temperature to mask and then add 3 coats of Spray Putty!!!



Tomorrow night will see a rub back with 400 grit, but the weather will probably be against me for further coats of spray putty. We shall see what the morrow brings!

[Kekotic]

Mark approximately how many hours all up have you spent on this so far?

[MH3.0R]

1st set was the rough cut out and filing, sanding, 2 hours.
2nd step was the rough fold in mesh, 1 hour.
3rd step was the prime and paint, 2 hours (broken between prime, sand, prime, sand, finish coat, sand, finish coat sand, finish coat).
4th step, sand and fibre glassing, 2 hours (broken into 2 x 1 hour sessions)
5th step, Body Filler, 1 hour (for 8 minutes of actual work!)
6th step, Sanding the Body FIller back with 100 grit, 2 hours (yes I did over fill and it took me that long with 100 grit to take it back....lesson learned).
7th step, Masking and Spray Putty x 3 coats, 2 hours (allowing for 10 minute drying intervals between coats).

Total so far, you can do the maths, not bovered!!!

Next steps...Sanding with 400 grit, Spray Putty x 3 coats, Sanding again, then maybe Final Coat x 2 with Sand in between with 400 grit. maybe another 4 hours.

I manage this by stealing windows of opportunity on my weekends and making sure the weather is right at the time (critical for fibreglassing). Except, now I would like to have it ready for the cruise, so I am making the most of the weather and daylight.

Also, in case you have not guessed, I am a rank amateur at anything to do with surface prep and finishing. Never before used any of the ingredients in this post. So, there has also been lots of reading and browsing other forums. In any case, for me it was not about the effort, just to do a DIY project for myself that could be done with off the shelf stuff.

[teK--]

Lookin good Mark. Seems you have more than enough materials to mod many, many grills

[MH3.0R]

Well, might just have to start a production line!

Nah, what was I thinking. I don't enjoy it that much, just the satisfaction of DIY.

[cruisn]

Coming along nicely Mark.

You look like a pro already.

[MH3.0R]

Well, there are a couple of wet runs, but nothing that was not intentional (to try an fill a couple of imperfections) and should sand out nicely. On to that now!