January 28, 2008
090's battery cover taken from the mold. The back has been
finished with filler and next the back and the front will
be primed in duratec gray. I am waxing the floorboard mold
to start making three floorboards. Because 090 will be the
first delivered car of the three 904's, we will consider the
first one to be for 090.
were also originally made from the plastic that wasn't too
durable (after 43 years), so we make the part out of fiberglass,
because it would be too expensive to make this floorboard
the way it was done in the old days. If this were done, the
plastic today would be durable enough to last a lifetime,
but not cost efficient for us. The picture of the three pigments
are what it takes to color neutral gel-coat so the floorboards
look exactly the same as they were originally, color and all.
The only way you can tell that it's not an original part,
would be to remove it to see the German cloth on the bottom.
dudes and dudettes think the original floorboards were gray...NOT!
I have a stash of old busted up floorboards, and they are
all this tan-green-gray color. The color varies a little,
but that's understandable. I use the bottom color to match
the gel-coat for a new part.
has now been sprayed with gel-coat. After the gel-coat dries
for 24 hours, the surface is sanded lightly to get rid of
any imperfections on the surface (imperfections will cause
the surface is sanded, I apply a slurry of milled fiber and
cabosil and brush it into all the surface dimples. These dimples,
if not filled with this slurry, would be air pockets and when
the part is released from the mold, they would be weak and
pop. I am applying one layer of 3/4 oz mat and will let it
a roller to remove air bubbles.
the other two layers of mat and one layer of cloth have been
applied, I will let the part sit and cure. Then the part gets
my baby buzz saw for the cutting, then if all goes well, the
part pops right out...as it did today.
product looks as good as an original brand-new part and because
the gel-coat is the color, the part will be very durable.
Big shoes might scratch it, but the scratches will always
be the same color.
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