DIY R53 Composite Hood

Discussion in 'Car Builds, Projects, Idea's Experiments' started by jerryb2005mcs, Mar 21, 2014.

  1. jerryb2005mcs

    jerryb2005mcs New Member

    Jan 13, 2013
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    You might think this a crazy project. So much easier to just buy one rather than make it yourself, but it's been something I've wanted to do for a long time.

    I've been playing with fiberglass and carbonfiber for a while. But this is the largest project I've ever taken on.

    I decided to keep it OEM style. I'll be able to use the stock mounting points and hood struts.

    So, here is the mold making process:

    Hood off the car and plugs in
    [​IMG]

    Adding flanges to the hood
    [​IMG]

    More flange work and filliting
    [​IMG]

    Gel coat
    [​IMG]


    Next mold I make will have a thicker coat gel

    Fiberglass
    [​IMG]

    Finished top part of hood mold
    [​IMG]

    Nearly finished bottom of hood mold
    [​IMG]

    So far it's coming along nicely. Since carbonfiber is expensive, I'll make the first part from these molds out of fiberglass.
     
  2. Dave.0

    Dave.0 Helix & RMW Powered
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    Nice project and pictures please keep posting your progress. :Thumbsup::popcorn:
     
  3. Metalman

    Metalman Well-Known Member
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    I'm going to love following this project....
    Please list ingredients if you please....:Thumbsup:
     
  4. ScottinBend

    ScottinBend Space Cowboy
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  5. cct1

    cct1 Well-Known Member
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    Wow, that's very cool--weigh it when you get the chance!:Thumbsup:
     
  6. Mr. Jim

    Mr. Jim Mudshark
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    Sweet! We did one for a TR6 autocross car back about 15 years ago. Keep the photos coming!
     
  7. MCS02

    MCS02 Moderator
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    This is really cool!
     
  8. cct1

    cct1 Well-Known Member
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    If you make one for the F56, you'll become a bazillionaire overnight...
     
  9. jerryb2005mcs

    jerryb2005mcs New Member

    Jan 13, 2013
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    Thanks for the comments!

    This hood has been a challenge to make. Lots of compound curves and overhangs that make mold making a pain. Lots of filleting, hole filling etc. But it's looking pretty good now.

    I've got the following materials into the mold:
    Top half, 32 oz of orange gel coat, 2 layers of 3oz fiberglass fabric, 2 layers of 1.5oz fiberglass mat. Over all there is about 4lbs of polyester resin.

    Bottom half is 32 oz of orange gel coat, 2 layers of 3oz fiberglass fabric and 2 layers of 1.5oz fiberglass mat. Same amount of polyester resin.

    With good size flanges vacuum bagging this thing should be easy. I've never made a part this big though so I'm learning a lot about how different resin flows across long sections under vacuum.

    Also I've learned a lot about getting the hardener mixtures right so that it doesn't catalyze too fast. And since I'm in the north and my shop doesn't have the best heater, not being able to keep temperatures right does mess with pot and cure times.

    As for making a R56 hood; I'd love to try it. I think it would be about the same amount of work. Will take a couple weeks to make the molds. All I'd need is a donor hood to work with! Anyone want to volunteer?

    I'll have more pictures after I pop the plug out of the bottom mold. Then next steps will be to fix any blemishes in the mold, polish it, and start making a hood! Can't wait.

    I'm curious about how heavy the final hood will be too. I'm expecting it to be about 12 lbs. The stock R53 hood, without lights, weighs about 38 lbs.
     
  10. Metalman

    Metalman Well-Known Member
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    Most excellent adventure....

    Take lots of pictures....
     
  11. jerryb2005mcs

    jerryb2005mcs New Member

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    I'm not the best documentor.
    Today I finished the bottom half of the mold.

    Here is the bottom mold.
    [​IMG]

    Top and Bottom together.
    [​IMG]

    Moving right along.

    Once I've got a couple blemishes in the gel coat fixed and the surface buffed I can start molding a hood! :cornut:
     
  12. N2MINI

    N2MINI MINI of the Month

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    How is this coming...
     
  13. GokartPilot

    GokartPilot Well-Known Member

    Jan 9, 2012
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    Very cool project! Please keep us up to date with lots of pics. Great job so far, look forward to the finished project.
     
  14. RallyMini370

    RallyMini370 Well-Known Member

    Mar 12, 2012
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    Not being a fiber glass chappy, why do you need a bottom mold? I thought only the top mold would be required as no one sees the inside. Anyway how's the bonnet coming along?
     
  15. Mr. Jim

    Mr. Jim Mudshark
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    I would :) that's the thing about a lot of fiberglass panels, they don't take the time to do it right and make the inside look good too.
     
  16. RallyMini370

    RallyMini370 Well-Known Member

    Mar 12, 2012
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    for a road car you have a point. For a rally car not so much.
     
  17. jerryb2005mcs

    jerryb2005mcs New Member

    Jan 13, 2013
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    Sorry, haven't been able to post much lately. Work on the hood is almost done.
    I've learned a heck of a lot in making this part. It's been one of the most complex pieces I've ever made.

    The compound curves make vacuum bagging very difficult but it was do-able!

    Here is the final result from my first pressing and doing some trimming.

    [​IMG]

    It's not perfect. I'll need to change up my bagging film to a more flexible type.
    Overall I'm really happy with how it turned out.

    Weight?
    The stock hood without the lights weighed about 35 lbs. The carbon hood weighs just 8 lbs.

    Here is a picture of the underside with made with the second mold. Pic taken before trimming or epoxying it in.

    [​IMG]

    Without it the top portion would be pretty saggy. This holds it all together and provides the support for the OE hood hings and light supports.

    I'm still working (slowly) on this and will post pictures of the hood on the car as soon as I can. It's been a hoot working on it!
     
  18. GokartPilot

    GokartPilot Well-Known Member

    Jan 9, 2012
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    I was talking to someone the other night about your project and was wondering where you were at with it. Awesome work, can't wait to see the end results and hear how it holds up on the road. Keeps the pics coming!
     
  19. jerryb2005mcs

    jerryb2005mcs New Member

    Jan 13, 2013
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    Test fitting the hood to the car. Just checking to see where I need to do more trimming. It needs a little more.

    [​IMG]

    I haven't bonded the two halves together again to see how well I can utilize the OE mounting hardware.
    I cut the holes for the hinges and even bolted up the strut.
    The OE struts are too strong for this hood. I'm not sure how many pounds of pressure they are but I'll need something closer to 15 lbs than whatever they are.

    Here are a few more pictures:

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Still have some work on trimming the excess carbon, getting the lights mounted and those struts. It's looking pretty good so far.
     
  20. GokartPilot

    GokartPilot Well-Known Member

    Jan 9, 2012
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    Totally agree! Looks great!

    Not knowing a lot about carbon fiber I was wondering if you had to build up support areas where things such as struts are mounted?

    Great pics, keep them coming!
     

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