simonnowis
12-03-2009, 05:02 PM
Disclaimer: The following is provided as a GUIDE ONLY, and neither myself nor Ozhonda take any responsibility for the outcomes of someone else doing the following. You follow these steps at your own risk!
Repairing Damaged Fibreglass EK9 Wing. Replacing the studs and cracks.
the only costs that came out of pocket was:
$100 dmged EK9 wing (thanks outatime)
$25 Fibreglass Repair Kit (Repco)
around $10 -10mm Bolts, 20mm in length, T.W. 8.8 inprinted on head (exact same bolts as previous studs on wing), Bigger Washers. (Bunnings)
Total out of pocket - $135
rest of stuff I had lying around the shed.
STEP 1: Inspect damage on Wing, the old studs were only held on by fibreglass only so it was easy to rip off..hmm not very strong.
http://i256.photobucket.com/albums/hh161/simonnowis/P080309_2219.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P080309_221901.jpg
STEP 2: Newer stronger bolts and bigger thicker washers. before assembling rough up the washers with sandpaper or even concrete footpath which I did. DO NOT use studs over 20mm in lengh! chizel off any excess fibreglass to ensure new studs fit flush in the old groove. trial fit the wing with new studs.
http://i256.photobucket.com/albums/hh161/simonnowis/P080309_2221.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P080309_222101.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P080309_2224.jpg
STEP 3: gluing the new studs on leave overnight, I used megapoxy 69(http://www.megapoxy.com/megapoxy69.htm) its the strongest epoxy I could get hold of. P.s. this is not the same megapoxy I used on my EK9 door trim DIY (http://www.ozhonda.com/forum/showthread.php?t=84837) , I used megapoxy PF a 3min poxy which can be easily broken off if necessary. As you want the studs to be permanent I recommend megapoxy 69 as it wont break off without breaking the actual wing. An alternative is to cut up tiny pieces of fibreglass and mix into resin to form a thick adhesive, DO NOT go over the nut.)
http://i256.photobucket.com/albums/hh161/simonnowis/P090309_152101.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P090309_1521.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P100309_1137.jpg
STEP 4: K&H Fibreglass repair kit, should include everything required except for mask. MUST wear protective mask for safety!!. Cut the fibreglass matt into small pieces required, The adhesive mixture is 12 drops of catalyst for ever 20ml of resin.
http://i256.photobucket.com/albums/hh161/simonnowis/P100309_1138.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P100309_1152.jpg
Firstly apply some mixture on the area with the brush then lay the fibreglass matt. brush over again with brush wet with adhesive mixture and build up. Run the brush through and make sure there are no air bubbles.
DO NOT build over the nut, or the wing will not sit flush on car.
http://i256.photobucket.com/albums/hh161/simonnowis/P100309_115802.jpg
STEP 5: Repair any damages with fibreglass. I did not care about making it neat as most of the damage was on the inner area where the studs are.
Once the fibreglass is all dry, the cracks, holes should be filled with putty, and sanded down to smooth surface. I used 220 grit, then 600 grit which I had lying around. I recommend Wet Sanding as resulted in smoother surface.
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1022.jpg
STEP 6: Once all the repaired area is smooth, wipe down to get rid of dirt, oil, grim etc. I used rubbing alcohol, but other solutions are ok, once dry and clean spray lightly with primer. I used two coats and wet sanded with 600/800 inbetween and finished with 1500grit until surface was perfect.
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1028.jpg
STEP 7: luckyily had a can of gloss black in the shed, so I painted the repaired areas to make it look clean. I did about 2-3 thin coats and polished it after.
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1213.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1518.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_151801.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1519.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1526.jpg
Luckily only damage was to the base of the wing.
STEP 8: Install Wing by pulling off back plasic. This will reveal two 10mm black nuts. there are 4 nuts all together holding the wing. unplug the rear brakelight and rear window water tube. The studs are held on more stronger then before and mounted perfectly. Note* feel free to trial fit during the whole diy process to ensure its correct.
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1529.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1549.jpg
Thanks For Reading...If you have any questions or suggestions please feel free to ask and comment. It was my first time fibreglassing and I can say its very similar to paper mashay!!:thumbsup: p.s. Plz Rep if you found this useful
Repairing Damaged Fibreglass EK9 Wing. Replacing the studs and cracks.
the only costs that came out of pocket was:
$100 dmged EK9 wing (thanks outatime)
$25 Fibreglass Repair Kit (Repco)
around $10 -10mm Bolts, 20mm in length, T.W. 8.8 inprinted on head (exact same bolts as previous studs on wing), Bigger Washers. (Bunnings)
Total out of pocket - $135
rest of stuff I had lying around the shed.
STEP 1: Inspect damage on Wing, the old studs were only held on by fibreglass only so it was easy to rip off..hmm not very strong.
http://i256.photobucket.com/albums/hh161/simonnowis/P080309_2219.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P080309_221901.jpg
STEP 2: Newer stronger bolts and bigger thicker washers. before assembling rough up the washers with sandpaper or even concrete footpath which I did. DO NOT use studs over 20mm in lengh! chizel off any excess fibreglass to ensure new studs fit flush in the old groove. trial fit the wing with new studs.
http://i256.photobucket.com/albums/hh161/simonnowis/P080309_2221.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P080309_222101.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P080309_2224.jpg
STEP 3: gluing the new studs on leave overnight, I used megapoxy 69(http://www.megapoxy.com/megapoxy69.htm) its the strongest epoxy I could get hold of. P.s. this is not the same megapoxy I used on my EK9 door trim DIY (http://www.ozhonda.com/forum/showthread.php?t=84837) , I used megapoxy PF a 3min poxy which can be easily broken off if necessary. As you want the studs to be permanent I recommend megapoxy 69 as it wont break off without breaking the actual wing. An alternative is to cut up tiny pieces of fibreglass and mix into resin to form a thick adhesive, DO NOT go over the nut.)
http://i256.photobucket.com/albums/hh161/simonnowis/P090309_152101.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P090309_1521.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P100309_1137.jpg
STEP 4: K&H Fibreglass repair kit, should include everything required except for mask. MUST wear protective mask for safety!!. Cut the fibreglass matt into small pieces required, The adhesive mixture is 12 drops of catalyst for ever 20ml of resin.
http://i256.photobucket.com/albums/hh161/simonnowis/P100309_1138.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P100309_1152.jpg
Firstly apply some mixture on the area with the brush then lay the fibreglass matt. brush over again with brush wet with adhesive mixture and build up. Run the brush through and make sure there are no air bubbles.
DO NOT build over the nut, or the wing will not sit flush on car.
http://i256.photobucket.com/albums/hh161/simonnowis/P100309_115802.jpg
STEP 5: Repair any damages with fibreglass. I did not care about making it neat as most of the damage was on the inner area where the studs are.
Once the fibreglass is all dry, the cracks, holes should be filled with putty, and sanded down to smooth surface. I used 220 grit, then 600 grit which I had lying around. I recommend Wet Sanding as resulted in smoother surface.
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1022.jpg
STEP 6: Once all the repaired area is smooth, wipe down to get rid of dirt, oil, grim etc. I used rubbing alcohol, but other solutions are ok, once dry and clean spray lightly with primer. I used two coats and wet sanded with 600/800 inbetween and finished with 1500grit until surface was perfect.
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1028.jpg
STEP 7: luckyily had a can of gloss black in the shed, so I painted the repaired areas to make it look clean. I did about 2-3 thin coats and polished it after.
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1213.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1518.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_151801.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1519.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1526.jpg
Luckily only damage was to the base of the wing.
STEP 8: Install Wing by pulling off back plasic. This will reveal two 10mm black nuts. there are 4 nuts all together holding the wing. unplug the rear brakelight and rear window water tube. The studs are held on more stronger then before and mounted perfectly. Note* feel free to trial fit during the whole diy process to ensure its correct.
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1529.jpg
http://i256.photobucket.com/albums/hh161/simonnowis/P120309_1549.jpg
Thanks For Reading...If you have any questions or suggestions please feel free to ask and comment. It was my first time fibreglassing and I can say its very similar to paper mashay!!:thumbsup: p.s. Plz Rep if you found this useful