That's a lot of moulds.

Quick little update while I finish up the next video.

I really tried to build myself a buffer so I could do all this off camera and not have yet another mould making video but coupled with a trip to Japan and other things, that didn't end up happening.

So continuing from the last episode / update. I got the rear lip fully block sanded, ended up sanding through to the fiberglass in a few spots so had to touch up some areas with another coat of primer but after a couple days of sanding from 240 - 1500 I was able to get a nice polish on the 2k primer.

The finish I'm getting from just my regular 2K filler primer seems to be a lot nicer than what I was getting with the polyester sealer I'd been using that cost about 3 times as much and sanded like a damn rock.

The only reason I'd been even spraying the sealer in the first place was because of the mishap I had with some expired release agent leading me to think I needed to spray a sealer when in fact a regular 2k primer seems to be completely fine. So one more step to cut out for anyone following along at home.

Adding the flanges always takes so much longer than I expect. I have to get over the urge to cut every little piece to the perfect shape and just get these things done way quicker. Adding these few pieces and getting some release agent on took me a whole day.

But once that was done I moved on to the gelcoat. The pot was really close to the end by this stage and honestly the coat I was able to get was a little thinner than I'd like.

I didn't have enough red tooling gelcoat to do the sides for this rear lip so I ended up just using some of my regular black gelcoat. It's not perfect and it actually ended up with a little bit of shrink back in the corners but luckily not on the actual part surface.

It didn't make any sense for me to spend another $280 on 4L of tooling gelcoat to do just these two pieces so eventually when I'm restocking I'll remake them.

I've been chasing issues with print through on my moulds lately and so I'm trying out a couple of new techniques on this one. The first is that I've doubled up my tissue layer so I've got 2 layers of 30gsm tissue before the 225 gsm chopped strand. The second is that I want to take the finished mould and leave it in the sun to bake for a day or so. That extra baking will make sure that the gelcoat has done all it's shrinking before I wetsand and polish so that once I've cut and buffed it the surface will stay like glass.

That's the last mould 'done'. Pretty big milestone but I guess there have been lots of those and since I'm just ready to wrap this thing up I'm not going to set here and savor it. I did think it would be interesting to lay out all the moulds that I have made for this project just to give a visual demonstration of how much fiberglassing there has been. These are just the moulds:

In total, to date for this project I have made 17 moulds or 25 individual mould pieces (for 2 and 3 piece moulds) and each of these moulds has produced at least 1 fiberglass part. Plus the original expanding foam forms and the 2 sets of 3D printed right side fenders.

That's well over 50 unique pieces that have been made just to get the car to this stage. I really had no idea just how time consuming this was going to be and I'm not sure if I'm going to go to this level on something again for a while.

The next step after polishing that mould is to quickly smash out a new fiberglass lip without all the holes in it and then I can fully get stuck in to the last bit of bodywork before sending these pieces out for paint.