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Old 10-01-2005, 05:41 PM
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Smoothing out a plug to make a composite mold?

Basically, what I want to do is make a CF dash. I have a stock dash that I will modify slightly, and then use that as my plug (the dash is a throw away). BUT, the dash, like a lot of factory vinyl dashes, has a texture to it. I want to smooth this out before I make the mold.

Whats the best way? Do I just modify the dash in the areas that I want, clean it all really well, then shoot the ENTIRE dash with high-build primer and smooth? Will it stick to the vinyl (or whatever the dash is made of; typical stuff).

Any ideas? Dash is above. Note I'll be changing some of the angles so that they aren't so much '90degrees', which should make things a lot easier for me. . The yellow is where I will change the angles; and the red area will disapear (among others)


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Old 10-01-2005, 06:32 PM
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What is the dash out of, from the 4spd marking I'm guessing 1970's camero?
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Old 10-01-2005, 08:10 PM
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Check out some of the threads on fiberglass and such that are here..look at the ones where we used fleece or old t-shirts for the layup..

Be really good to yourself and test the resin to see that it sticks in an inconspicous spot..

Then lay a layer of fleece or t-shirt over the dash and soak it with resin so it is completly saturated..use bondo in the corners tha tyou wish to change and glass over any holes that you will not need..

Once that is all done spray a coat of gel-coat and sand that until you are satisfied withe the finish and then pull your mold from that..

Be careful not to change the size of the piece very much specially in the areas where it has to mount or fit up to the existing car..Check out these guys for materials

Good luck

I have tried most all of it and now do what is known to work..
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Old 10-04-2005, 09:14 AM
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This sounds like a really interesting project and one that a lot of us could learn from.

I hope you'll post your progress.
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Old 10-07-2005, 09:14 PM

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it would prolly be easier to make the mould and then spray that with a polyester primer and sand it smooth. duratec has a good one for this use.
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Hi-build primer would work. So would a thin layer of Bondo. Anything that fills the grain and sticks well enough to tool into shape. Finish with some primer wet sand to perfection, spray with any high gloss catalyze urethane. Let that cure for about a week. Then wax with Partsall or other good MOLD RELEASE wax ( DON'T use car wax!!!) and spray with PVA and your gel coat/'glass mold will pop right off with zero damage to your plug, guarantee.
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