fbi90909's TC LMS 5400 15 + Saz3000D rebuild + fiberglass

[fbi90909 5,000+ posts]

well i got pretty busy today.

since i got the rear deck cut and the box already in place it gave me the opportunity to setup the ports so i can affix them to the rear dash panel prior to glassing. why? well, so i did just that.

i got me some Popsicle sticks and my hot glue gun and started gluing the flare onto the rear dash panel. now the entire port is in place going down to the inside of the enclosure. with that, i know when i'm done glassing the rear dash panel, i will have proper fitment of the port.

well, there really isn't much explaining i can do w/oi pics so i'll explain as i go on.

test fitting the ports to find a balancing view

gluing the Popsicle sticks for support.

fuck you scissors!

home made band aid. lol, i know yall have done these before

back to work

panel out of the car flares glued down

 

[fbi90909 5,000+ posts]

bottom side taped, why? ok, what i need to do first before i flush the top side of the panel is basically create a mold for the flare to rest on after i get the bottom done, i'll then remove all the Popsicle sticks and hot glue. since the flare will have a resting point, and fleecing the top side of the panel should net me a smooth rear dash panel.

next i spread a nice thick coat of wax, i used a paste wax for the release agent. i hope this works as it's a paste. last time i used a cream/watery based wax and it worked ok.

now time for glassing!

one of my preparations for glassing is i tear small patches of fiberglass and place them in a container. i use small patches because it's a lot easier to work around with in corners or on curved surfaces. this mat is 3/4oz. i wish i got .5oz but i can still work with 3/4oz.

tear, don't cut! frayed glass is better then edge glass when bonding!

 

[fbi90909 5,000+ posts]

size of patch

less than 1 yard

glass time!

i didn't have any mixing cups in which i will pick up tomorrow so i made do with a dasani bottle.

when i glass i use a small amount of resin. truthfully when glassing you only need a small amount, why? cause you just want to wet the mat, not soak it.

this is how much resin i use each time i dip into the cup

first i spread some onto the work area to get a tacky surface so when i do lay glass, it stays on there.

first patch

second patch

working it in

another patch

 

[fbi90909 5,000+ posts]

working my way around

at this point i have about 3 layers. look at how much resin i still have in the cup!

at this point that resin started to gel on me. oh well, new batch!

second batch, even smaller for the second flare.

both sides glassed with 3 layers in most areas.

well, i'll let that cure and first thing in the morning i'm going to go out and pick up a few supplies. i'm pretty much going to focus on the rear panel the whole time tomorrow.

on a side note, i was thinking, with the amount of air going towards the rear window, that shit's going to flex a lot lol.

 

[Pioneer~Saturn 5,000+ posts]

Nice //content.invisioncic.com/y282845/emoticons/smile.gif.1ebc41e1811405b213edfc4622c41e27.gif keep it up

 

[528hz 10+ year member]

What's the ETA?

Great worky!

 

[fbi90909 5,000+ posts]

Nice //content.invisioncic.com/y282845/emoticons/smile.gif.1ebc41e1811405b213edfc4622c41e27.gif keep it up

will do!

What's the ETA?
Great worky!

today was my last day for work until the 26th of may. so i got all the time in the world at the moment. i'm hoping to be done by the 15th. i can almost be sure i'll be done by the 15th.

 

[mmouse57 10+ year member]

did you make the box disasemble it then glue and screw it together back in the trunk as if the box will not fit already made outside the trunk? so if you ever remove the box your taking a hammer to it to get it out?

just curious //content.invisioncic.com/y282845/emoticons/smile.gif.1ebc41e1811405b213edfc4622c41e27.gif nice build log

mouse

 

[bhsdriller 10+ year member]

looks good so far.

Gonna be an awesome set up when done

 

[KyngHype 10+ year member]

This is going to be awesome //content.invisioncic.com/y282845/emoticons/fyi.gif.9f1f679348da7204ce960cfc74bca8e0.gif

 

[fbi90909 5,000+ posts]

did you make the box disasemble it then glue and screw it together back in the trunk as if the box will not fit already made outside the trunk? so if you ever remove the box your taking a hammer to it to get it out?
just curious //content.invisioncic.com/y282845/emoticons/smile.gif.1ebc41e1811405b213edfc4622c41e27.gif nice build log

mouse

yes, i assembled the box outside of the car with screws only as i needed to test fit it into the car to verify whether or not it had to be built in the trunk as i had to like my last box. upon finding out it needed to be disassembled to be put in the trunk it is a good thing there is no glue involved until actually settling it in.

when it comes to having to take the box out the car, a chisel and a rubber mallet are my friends. same procedure i took with the last box.

and thanks

 

[fbi90909 5,000+ posts]

looks good so far.
Gonna be an awesome set up when done

thanks. i hope it turns out awesome.

 

[fbi90909 5,000+ posts]

This is going to be awesome //content.invisioncic.com/y282845/emoticons/fyi.gif.9f1f679348da7204ce960cfc74bca8e0.gif

i hope so.

 

[5SICK2]

Any pictures for today? //content.invisioncic.com/y282845/emoticons/smile.gif.1ebc41e1811405b213edfc4622c41e27.gif

 

[fbi90909 5,000+ posts]

alright today started out pretty early. got my measuring cups and mustard pumps at a west marine for my resin and got to work.

i started out with trimming some of the excess strands of glass that didn't want to adhere properly around the molds. after the trimming i added a few layers of glass to extend the surface area of the mold to the panel so when i remove the mold i will have a large surface area to epoxy the mold back in place.

after that i set the rear panel in the sun and began to work on something else.

i started with removing the weather stripping of the trunk

THANK YOU HONDA! i thought there would be a mess of glue. thankfully the weather stripping junda just clips on pretty snugly.

with that out of the way i decided to start laying blue tape around the area of the front beauty panel will run off to.

but before that i haven't showed ya how my sealed holes turned out. they turned out pretty good actually.

after all the taping

well, at this point i can't start on the front beauty panel untill i get the baffle glued. before i even glue the baffle down i need to glue the ports. before i glue the ports i need to complete the rear dash panel. soooo i decided to start on the trunk beauty panel.

started with the taping