DIY front lip. How do I create a mold to replicate this? Lots of pics

[defconskylude]

Can someone please help explain on how to create a master mold so i can replicate this in case I crack my lip from daily driving?

I know I can easily take this to a shop to get it done, but it will cost a lot of money and I'd really like to learn this first hand on how the process works. I have an idea of how it works but I need confirmation from someone that has experience in replicating front lips.

Also I'm getting mixed up with the terminology when using the words "cast", "mold", "plug".

Do I use a plug to create a master mold?
Then from a master mold, I can create a production front lip?

Here's how I think it should work. Please correct me if I'm going at it the wrong way.

1) After I pry the lip from the OEM bumper, I sand it down smooth
2) use bondo/body filler to fill in gaps, create some finer details and make it even with more sanding
3) once i get the desired look, i use a polyurethane release agent or waxing compound, rub the entire lip
4) let the wax dry and then rub it off
5) layer the lip with gelcoat
6) layer the lip with resin
7) layer the lip with fiberglass
8) use a roller to air out the bubbles and even out the fiberglass
9) let it dry for a day
10) pull and pry out the production lip from the master mold? that's it?


Here's my setup. Originally I did the home depot front lip.
http://preferredvalleyhomes.com/IMG_0849.JPG
http://preferredvalleyhomes.com/IMG_0855.JPG
http://preferredvalleyhomes.com/IMG_0853.JPG
http://preferredvalleyhomes.com/IMG_0842.JPG

Here's the photo journal that I did. This is my first time doing this with very limited knowledge.

Day 1

Had some free time today to finally start on my custom front lip.

Tomorrow I plan to fiberglass it to the bumper to get better fitment.
Monday will be sanding and primer

Took about 2.5 hours to get this part done. (template, foam, masking)

Things needed:
cardboard to trace a template
styrofoam
sharpie
cutting knife
ruler
painters tape
resin
fiberglass
60 grit sandpaper
220 grit sandpaper
1200 grit sandpaper
dremel for trimming
wax or PVA
bondo/body filler


This is the shape that I'm trying to achieve
http://i65.photobucket.com/albums/h223/acuragsrx/IMG_8059-2.jpg

http://preferredvalleyhomes.com/IMG_0085.jpg
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[defconskylude]

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[defconskylude]

another 2 hours today.

i used simple green to clean up the OEM bumper and then masked it with painters tape. i then used a much stronger packaging tape on the OEM bumper to the lip and sprayed it with water base polyurethane to act as a releasing agent. this means i get to remove the fiberglass from the bumper easily when i pry the front lip.

i cut up an old tshirt into strips and wrapped the middle part of the lip. basically each stripped was stretched on the top and bottom to get that flat angle.

i brushed the tshirt in resin so it'll be hard tomorrow for fiberglassing. it was getting dark so i only had time to fiberglass the right side of the lip

i have a full day tomorrow for more fiberglassing.

http://preferredvalleyhomes.com/IMG_0173.jpg
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http://preferredvalleyhomes.com/IMG_0188.jpg
http://preferredvalleyhomes.com/IMG_0189.jpg

[defconskylude]

another 2 hours today

its not the prettiest right now.

few lessons learned:
i need to figure out a better way to hold up the lip instead of using tape.

would be nice to have an air compressed staple gun to staple the tshirt strips

i need a better stand to hold up the bumper instead of a using a cardboard box.

learned that it wouldve been better to just wrap the entire lip in aluminum foil instead of painters tape.


anyways i just finished up fiberglassing the entire lip. it will take a full day to dry up.
i will sand down the lip using 60 grit sandpaper and then bondo/body filler to fill up uneven gaps. then use 220 grit sandpaper to smooth it. then use 1200 wet sanding paper for a glass finish.

time to find DIY articles on how to make a master mold.

http://preferredvalleyhomes.com/IMG_0190.jpg
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[defconskylude]

all done drying. i will pry the lip tomorrow, trim the edges and i may need to add more fiberglass for more strength

i cant wait to sand this thing down.

as you can tell i eliminated the gap in the middle. i realize i can do other variations with this by making middle area more of a straight edge version and a rounded edge version.

right now i have the middle area as a pointed arrow to match the pointed OEM bumper and pointed grill

http://preferredvalleyhomes.com/IMG_0203.jpg
http://preferredvalleyhomes.com/IMG_0204.jpg
http://preferredvalleyhomes.com/IMG_0205.jpg
http://preferredvalleyhomes.com/IMG_0206.jpg

[defconskylude]

i had about 1.5 hours today to pry the lip off and trimmed some of the excess fiberglass strands using a dremel.

there's definitely some uneven parts of the lip so i will be doing some bondo/body filler. this will make it easier for me to sand it down smooth. i still need to add some tabs using fiberglass for the middle area so i can use double sided tape when its done. also need to add more fiberglass in the inside of the lip.

http://preferredvalleyhomes.com/IMG_0207.jpg
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http://preferredvalleyhomes.com/IMG_0232.jpg

[hondaEK4]

I don't know anything about molding but good job on the lip.

[felixd]

Props for the DIY !!!

[defconskylude]

had some free time today.

i sprayed some foam in the middle since i wanted to redo the shape
put some bondo over the entire lip
i ran out of bondo so i need to buy some more to fill in some gaps
sanded some of it down. i really hate sanding. i have a long way to go.

also test fitted some side skirt splitters. eventually those will be paint matched along with the front lip



http://preferredvalleyhomes.com/IMG_0355.jpg
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[defconskylude]

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[defconskylude]

inspired from the type S rear. in this case i just flipped the shape vertically to match my exhaust tips.

youll see some side skirt splitters in the middle. i plan to paint match it with the rest of the kit in the future

i taped up the rear bumper first
brushed PVA as a releasing agent
let PVA dry
brushed resin all over the bumper
layed fiberglass
brushed resin all over the fiberglass
let it dry for a few hours
cut up some styrofoam for shaping
used hot glue to make it stick
i will wrap the styrofoam in foil with 3M adhesive spray
then fiberglass over the styrofoam/foil
let it cure 24 hours
pull out the plug
retest fit the plug
lay bondo
sand and smooth

http://preferredvalleyhomes.com/IMG_0360.jpg
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[defconskylude]

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[niiCk]

CHUNKY!
haha looks good though.
props for DIY, wouldnt have the guts to work with fibreglass on a pretty new car lol

[defconskylude]

had some time to work on the mugen replica side skirts off my 01 prelude

Test fitting. length wise it fits well against the OEM mud guards
http://preferredvalleyhomes.com/IMG_0427.jpg
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cleaned some of it up with simple green
http://preferredvalleyhomes.com/IMG_0436.jpg
http://preferredvalleyhomes.com/IMG_0437.jpg
http://preferredvalleyhomes.com/IMG_0438.jpg




taped it up
http://preferredvalleyhomes.com/IMG_0439.jpg
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http://preferredvalleyhomes.com/IMG_0441.jpg
http://preferredvalleyhomes.com/IMG_0442.jpg
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polishing compound used as a releasing agent on over the tape
http://preferredvalleyhomes.com/IMG_0444.jpg



1st layer of fiberglass done.
ill be adding 2 more layers of fiberglass after it cures for a day.
ill then pop it off the plug, do some trimming for perfect fitment.
http://preferredvalleyhomes.com/IMG_0445.jpg
http://preferredvalleyhomes.com/IMG_0446.jpg
http://preferredvalleyhomes.com/IMG_0447.jpg


stay tuned...

[tron07]

top notch DIY....

[BIGTYM]

that was awesome. big props for DIY'ing ur own kit

[defconskylude]

had to respray some foam underneath the lip to fill in some gaps. will smooth it out afterwards with sanding and bondo
http://preferredvalleyhomes.com/IMG_0448.jpg
http://preferredvalleyhomes.com/IMG_0449.jpg

side skirts 2nd layer of fiberglassing.
ill pry it off tomorrow
http://preferredvalleyhomes.com/IMG_0450.jpg
http://preferredvalleyhomes.com/IMG_0451.jpg

pryed the rear lip off.
some of the styrofoam pieces came off. ill have to reglue them and put bondo over it.
rear lip will be trimmed, refitted and layered with bondo
http://preferredvalleyhomes.com/IMG_0453.jpg
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my full lip kit
http://preferredvalleyhomes.com/IMG_0463.jpg
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http://preferredvalleyhomes.com/IMG_0465.jpg
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[asshat]

thread title is misleading, I thought you were asking on how to do it. good stuff.

[defconskylude]

yea i was doing a copy and paste from a fiberglass forum and made the mistake of making this title here. i cant rename the title.
although i did learn how to make the negative mold though.

[defconskylude]

pryed off the side skirts and trimmed off some of the foam on the lip
http://preferredvalleyhomes.com/IMG_0473.jpg
http://preferredvalleyhomes.com/IMG_0474.jpg
http://preferredvalleyhomes.com/IMG_0475.jpg

mounted it with painters tape to check what needs to be trimmed
http://preferredvalleyhomes.com/IMG_0476.jpg
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i trimmed off the sideskirts. i need to add fiberglass tabs on both ends and top side so it can be held on with double sided tape and tapping screws. man it looks clean.
i just need to put bondo and smooth it out
http://preferredvalleyhomes.com/IMG_0492.jpg
http://preferredvalleyhomes.com/IMG_0493.jpg
http://preferredvalleyhomes.com/IMG_0494.jpg
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time to do some foam trimming.
ive taped a ruler and drew a black line with a sharpie so i can shave the bottom of the lip and even it out
http://preferredvalleyhomes.com/IMG_0498.jpg
http://preferredvalleyhomes.com/IMG_0502.jpg
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http://preferredvalleyhomes.com/IMG_0507.jpg

its about 9pm and my wife is asking for attention. calling it a night
to be continued tomorrow

[mugen_ctr]

Fark thats so awsum, seeing this, im gonna steal ur idea and use it in my school projects, but on my civic, lol

Wouldnt it been easier if u had jus used clay, not the earth clay but the stuff they use in proper modeling cars an that? than create a mold from that clay model?

[defconskylude]

Fark thats so awsum, seeing this, im gonna steal ur idea and use it in my school projects, but on my civic, lol

Wouldnt it been easier if u had jus used clay, not the earth clay but the stuff they use in proper modeling cars an that? than create a mold from that clay model?

ive used clay before on my first project with the foglight housing. personally it was kinda hard to mold clay because of the symmetry. i just eyeballed it and i was in a hurry which is why the fitment isnt that great. i switched it up to styrofoam since it was cheaper and easier to sculpt.

[Ken-f]

Lol. You really did mean LOTS of pics. After looking at that, it looks good, but I would just get it done by pros looking at how much effort it takes!

Can't wait to see the result! Looks like its coming along nicely.

[Lemonhead]

really impressive, defconskylude. can't wait to see more later.

[defconskylude]

Lol. You really did mean LOTS of pics. After looking at that, it looks good, but I would just get it done by pros looking at how much effort it takes!

Can't wait to see the result! Looks like its coming along nicely.

thanks

the pros charge about $5,000-$9,000 USD for a custom kit made from scratch. i dont have that kind of money which is why i went the DIY route.

[mugen_ctr]

agreed, and plus if you do decide to make a few more molds, u can sell them :)

[defconskylude]

woot. 3 day weekend to work on my car fulltime.

had some time to trim the edges for fitment
put some body filler on the rear.
also i changed up the design which i think looks a bit cleaner

http://preferredvalleyhomes.com/IMG_0510.jpg
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i had to do some trimming in the middle for fitment
http://preferredvalleyhomes.com/IMG_0515.jpg


add a tab on the rear side skirt
also trimmed some excess fiberglass.
i will put body filler on the side skirts tomorrow
http://preferredvalleyhomes.com/IMG_0524.jpg
http://preferredvalleyhomes.com/IMG_0525.jpg
http://preferredvalleyhomes.com/IMG_0526.jpg
http://preferredvalleyhomes.com/IMG_0527.jpg

here's the rear lip detached.
i cut out the middle piece and clean up around it.
i plan to put a painted black grill when its done.
ill put another layer of body filler tomorrow

http://preferredvalleyhomes.com/IMG_0528.jpg
http://preferredvalleyhomes.com/IMG_0529.jpg
http://preferredvalleyhomes.com/IMG_0530.jpg
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http://preferredvalleyhomes.com/IMG_0535.jpg
http://preferredvalleyhomes.com/IMG_0536.jpg

then its just a lot of sanding

[Simonnn]

Amazing stuff! can't wait to see the final product :D

[defconskylude]

added more fiberglass in the middle for better fitment.
then layered it with bondo
i still have to trim and clean up parts of the lip with my dremel
then its just sanding, sanding, sanding

http://preferredvalleyhomes.com/IMG_0537.jpg
http://preferredvalleyhomes.com/IMG_0538.jpg
http://preferredvalleyhomes.com/IMG_0539.jpg
http://preferredvalleyhomes.com/IMG_0540.jpg
http://preferredvalleyhomes.com/IMG_0541.jpg
http://preferredvalleyhomes.com/IMG_0542.jpg
http://preferredvalleyhomes.com/IMG_0543.jpg
http://preferredvalleyhomes.com/IMG_0544.jpg
http://preferredvalleyhomes.com/IMG_0545.jpg
http://preferredvalleyhomes.com/IMG_0546.jpg
http://preferredvalleyhomes.com/IMG_0552.jpg
http://preferredvalleyhomes.com/IMG_0553.jpg
http://preferredvalleyhomes.com/IMG_0555.jpg
http://preferredvalleyhomes.com/IMG_0556.jpg
http://preferredvalleyhomes.com/IMG_0557.jpg
http://preferredvalleyhomes.com/IMG_0558.jpg
http://preferredvalleyhomes.com/IMG_0559.jpg
http://preferredvalleyhomes.com/IMG_0561.jpg
http://preferredvalleyhomes.com/IMG_0562.jpg
http://preferredvalleyhomes.com/IMG_0563.jpg
http://preferredvalleyhomes.com/IMG_0564.jpg
http://preferredvalleyhomes.com/IMG_0565.jpg
http://preferredvalleyhomes.com/IMG_0566.jpg
http://preferredvalleyhomes.com/IMG_0567.jpg
http://preferredvalleyhomes.com/IMG_0568.jpg

[nxn75u]

subscribed to this awesome thread!

[euromandeluxe]

holy shit, this is epic, nice work

[tiksie]

Wow.




Speechless.

Great work man.

[d_evilz]

wow! so much pics
looking good
cant wait to see the final product as well!

[integral90]

Any updates??

[defconskylude]

here's an update

i have to put an indefinite hold on this project. i do not have the time at the moment since my wife just delivered a new born son so my priorities have changed. after 36 hours of labor he was accidently born in our kitchen floor. we were on our way to the hospital, i ran out to get the car for my wife, i walked back in to open the door and my wife squatting in a pool of blood holding our son in her arms. i called the paramedics and my wife and son were taken to the hospital. he's perfectly healthy and fine. so im a first time dad and its been a life changing event.

when i have more time, i will definitely come back and complete this project.

thanks all. to be continued....

http://preferredvalleyhomes.com/kaidan.jpg
http://preferredvalleyhomes.com/kaidan1.jpg

heres a more detailed story

on 7/9/10, after 36 hours of early labor and irregular contractions between 5-12 minutes, we were on our way to the hospital and the baby decided to scare the crap out of us by coming out in our own kitchen home. my wife completely did not go through active labor NOR transition (pushing). i went to get the car, my wife was behind me coming down the stairs, as i opened the door to get my wife, i saw her squatting in a pool of her own blood holding our baby. for a split second i thought my wife was going to die due to all the blood loss and i thought my son was going to die because of the way he was born. my wife said she felt him coming out so she decided to squat and pull him out. with the rush of adrenaline, i ran to my wife and saw my son staring at me and suckling. i told my wife to breast feed on the spot and keep him warm with stimulation. i called 911 for the paramedics and they gave me instructions on what to do. i literally tied the umbilical cord with a shoe lace and made sure that my son's mouth and nose was clear so he can breath. the paramedics came in 5 minutes and took us to the hospital. he was born 12:09am. i went back home around 4am to clean up all the blood in our kitchen. i finished at 5am and as i was driving back to the hospital. i was at a stop light and just replayed all the events that had happened in my head and just broke down in happy tears and realized how lucky we were.

btw, our birth plan was to deliver in a hospital naturally and no medical intervention like epidurals, pitosin, c section, etc. we'd only consider those if it was really needed. well my wife got her wish.

its been two weeks and we're all fine now.

he's full term. 6 lbs 10oz 21in long

Kaidan Cole. im calling him "Kai" for short

[defconskylude]

just bought a new lip. its a 02-04 RSX Type R replica made of polyurethane
this was the actual shape that i was trying to achieve.
i figured it would be easier to just modify an existing front lip and just cut it up in certain areas and just extend it using fiberglass.

when i get more time i can tackle this. this will be a lot easier and less sanding involved.

http://preferredvalleyhomes.com/tsxlip0.jpg
http://preferredvalleyhomes.com/tsxlip1.jpg
http://preferredvalleyhomes.com/tsxlip1a.jpg
http://preferredvalleyhomes.com/tsxlip2.jpg
http://preferredvalleyhomes.com/tsxlip3.jpg
http://preferredvalleyhomes.com/tsxlip4.jpg
http://preferredvalleyhomes.com/tsxlip5.jpg
http://preferredvalleyhomes.com/tsxlip6.jpg
http://preferredvalleyhomes.com/tsxlip7.jpg

[Lemonhead]

here's an update

i have to put an indefinite hold on this project. i do not have the time at the moment since my wife just delivered a new born son so my priorities have changed. after 36 hours of labor he was accidently born in our kitchen floor. we were on our way to the hospital, i ran out to get the car for my wife, i walked back in to open the door and my wife squatting in a pool of blood holding our son in her arms. i called the paramedics and my wife and son were taken to the hospital. he's perfectly healthy and fine. so im a first time dad and its been a life changing event.


congratulations mate.
another successful DIY project on the kitchen floor.. amazing! cheers

[defconskylude]

here's some progress. i still need to finish fiberglassing the left side.

http://preferredvalleyhomes.com/IMG_0007a.jpg
http://preferredvalleyhomes.com/IMG_0010a.jpg
http://preferredvalleyhomes.com/IMG_0011a.jpg
http://preferredvalleyhomes.com/IMG_0015a.jpg
http://preferredvalleyhomes.com/IMG_0020a.jpg
http://preferredvalleyhomes.com/IMG_0021a.jpg
http://preferredvalleyhomes.com/IMG_0022a.jpg
http://preferredvalleyhomes.com/IMG_0003a.jpg
http://preferredvalleyhomes.com/IMG_0005a.jpg
http://preferredvalleyhomes.com/IMG_0008a.jpg
http://preferredvalleyhomes.com/IMG_0012a.jpg
http://preferredvalleyhomes.com/IMG_0013a.jpg

[d_evilz]

Congratulations on your son, defconskylude
nice update

[defconskylude]

finished fiber glassing the left side.
trimmed some of the lip
ill pry the lip off next and start adding body filler
then sanding

http://preferredvalleyhomes.com/lip02a.jpg
http://preferredvalleyhomes.com/lip02b.jpg
http://preferredvalleyhomes.com/lip02c.jpg

[curtis265]

You are, the most insane DIY guy i've ever seen..
Even DIY birth

[Tekkenforce]

^ Lol @ ur comment haha DIY Birth

[8700s14]

great diy project, must say, after all the time you put in to the original front lip, its a shame it won't be finished!

[defconskylude]

great diy project, must say, after all the time you put in to the original front lip, its a shame it won't be finished!

thanks.

eventually i will finish the 1st lip.

i just bought a full type s kit as a daily driver until i finish my custom kit

[defconskylude]

i forgot to post some updates on these

pryed the lip off the bumper
trimmed the lip
added a layer of body filler

next....sanding, adding fiberglass underneath the lip


http://preferredvalleyhomes.com/IMG_2164.jpg
http://preferredvalleyhomes.com/IMG_2165.jpg
http://preferredvalleyhomes.com/IMG_2166.jpg
http://preferredvalleyhomes.com/IMG_2167.jpg
http://preferredvalleyhomes.com/IMG_2168.jpg
http://preferredvalleyhomes.com/IMG_2169.jpg
http://preferredvalleyhomes.com/IMG_2180.jpg
http://preferredvalleyhomes.com/IMG_2170.jpg
http://preferredvalleyhomes.com/IMG_2172.jpg
http://preferredvalleyhomes.com/IMG_2175.jpg
http://preferredvalleyhomes.com/IMG_2176.jpg

[fmunir]

your rims look cool where did you get them

[furythree]

god u are one cool insane dude defcon. ur baby probably crawled out himself, to save u the trouble of getting out ur car "its ok dad, ill catch the ambulance, u finish doing up ur car!" lolz

[defconskylude]

your rims look cool where did you get them

theyre used infinit G35 coupe rims

18x8
+30 offset
225/40/18 tires

[defconskylude]

god u are one cool insane dude defcon. ur baby probably crawled out himself, to save u the trouble of getting out ur car "its ok dad, ill catch the ambulance, u finish doing up ur car!" lolz

hahaha ;)