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Step 8: Laying Fiberglass in Mold - Rear Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Step 9: Mounting to Scooter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Step 10: Headlamp Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Step 11: Finishing Touches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Step 12: Pictures in Action... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
http://www.instructables.com/id/Mini-Cadillac-Body/
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Image Notes 1. In this photo I have 4 foam board panels glued together, and I am beginning to carve the overall shape. I drew the contours of the details on the board first and began cutting away what wasn't necessary. 2. Notice that the rasp puts off a great deal of blue fuzz, which, because of the static electricity, sticks to EVERYTHING. I used a canvas drop cloth, and swept & vacuumed every time I worked on the car, and I still could not get it all up. This drove my wife crazy.
Image Notes 1. Here is a photo of me adding more foam boards to the front section to make it longer. I am glad that the foam boards are relatively inexpensive.
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Image Notes 1. This view of the front section shows how I repositioned the angle of the windshield by simply sawing it straight across at the bottom, then sawing a better bevel, before gluing and pinning it in place. If you look closely, you can see the two long wooden pins (toothpicks) I inserted to hold it while it glued. After the glue set, I had to do minimal shaping to get it to look right. This is also the first view with the bullet bumpers in place.
Image Notes 1. Here I have both sections fairly far along. As you can see I am adding length to the rear section. With far less detail, the rear was MUCH easier to shape than the front.
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Image Notes 1. In order to smooth the dried joint compound, I found that a sanding screen worked quite well in getting the rough spots down very quickly. I did not use a sanding block until I had the shape somewhat close to finished. On occasion, I also used the side edge of a stiff spatula to scrape surfaces smoother.
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Image Notes 1. This next photo shows the front end pointing straight up so that I could fill in the holes where the front grill and the headlights are to be. I had to fill them with a somewhat loose plaster of paris mix in order to have the eventual mold come off easily. If I had not filled these areas and left it ragged, the mold (also to be made of plaster of paris) would have rough areas to grab onto, and would probably not come off so easily.
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Image Notes 1. Here are the two sections somewhat ready for molding& the only thing I want to add at this time are the Cadillac Logos. It was a good feeling to know that I had reached this point in the project. 2. Cutout notch to allow for the steering column. 3. Cutout to allow for the seat post.
Image Notes 1. Rough-looking emblem... but that is OK. I'm going to sand it down anyway.
Image Notes 1. These areas need additional sanding to get nice and smooth.
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Image Notes 1. This is what my Cadillac looked like with all 4 plaster of paris panels in place.
http://www.instructables.com/id/Mini-Cadillac-Body/
Image Notes 1. This is a small triangular plywood angle meant to strengthen the transition between the hood and the front section. Make sure that these aren't positioned where you will eventually be cutting out for the grill. 2. On either side of the cast you can see the plaster side mold panels laying down after removal from the cast. I numbered them to help me remember in which order they were made. (assembled in the same order is assured to be simpler)
Image Notes 1. The edges of the fiberglass sides are rough, but not a problem as you will trim this off later. Just do your best to remove air bubbles when laying in the fiberglass cloth. 2. Hole slot for the steering column.
Image Notes 1. Free from the mold. It was a great feeling to see it looking this good.
http://www.instructables.com/id/Mini-Cadillac-Body/
Image Notes 1. All four mold panels in place. Fiberglass matting cloth laid into the mold with the resin. I applied 2 or 3 layers of cloth...trying to achieve a cast which was 1/8" or so thick. Areas of transition or thin areas I may have reinforced with additional layer(s).
http://www.instructables.com/id/Mini-Cadillac-Body/
Image Notes 1. The back of the rear mold section did not release so easily. I must not have applied enough mold release. I had to chip it off in a few pieces. Oh well, not that big of a deal.
Image Notes 1. The black part is an upside-down clamp-on bike book rack that has been stripped of the plastic book holder. 2. This is flat steel bar which has been bent to shape using a propane torch and pliers. Mark where you want to bend with a sharpie, heat up that line with the torch till it starts to glow red and bend it at that spot. It is fairly easy. Be VERY careful not to burn yourself. Let it cool, and drill holes to mount it.
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Image Notes 1. I felt that this end pointed down too much, so I added an angle-iron cross member onto the back section's support structure.
Image Notes 1. This T-section helps to raise the front of the rear section, and it also provides additional stability.
http://www.instructables.com/id/Mini-Cadillac-Body/
Image Notes 1. Wood dowels fiberglassed into the "bullet" bumpers for strength.
Image Notes 1. Wood block epoxied to the underside of the hood, behind the headlamp hole. 2. Key-type hose clamp screwed to the wood block. 3. I used a Dremel tool to carefully cut holes for the flashlight "headlamps".
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Image Notes 1. One day I was driving around town and I saw, on the side of the road, this actual car's grill. I pulled to the side of the road, and picked it up, cut it up, and hotglued it in my mini Cadillac. I appreciate someone's sacrifice for my mini Cadillac. 2. This is a good view of the wood strips used to reenforce the bottom edge of the front bumper. This was important because I sometimes run into trash while driving on the parade routes. 3. Embedded plywood mounting board fiberglassed under the hood, and well slathered with resin and cloth. If you look closely you can see the 4 holes for bolting it to my scooter's frame.
Image Notes 1. You can see a few damaged spots where the aluminum tape was torn from me running into things... 2. More damage. I need to put more aluminum tape here.
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3. Lining the headlamp area with the shiny aluminum makes a nice effect when the lights are on. 4. New grill donated by some unfortunate car owner. Thanks.
Image Notes 1. The grill looks AWESOME. Compare to the first photo in this Instructable to see what I mean. It sure beats hardware cloth. 2. Elvis on a date with Ann Margaret... post divorce.
Image Notes 1. Check out my Mini Teardrop Trailer Instructable. 2. I drove my rig to our local Art Market one Saturday. It was well received.
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Image Notes 1. The Rolling Elvi in true form, rolling in the Krewe of Muses Mardi Gras parade. We have a GREAT time, and strive to please the throngs of fans.
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Feb 28, 2013. 10:39 AM REPLY
seamster says:
Nice work! I'm glad you took the time to post this.
spratjack70118 says:
Thanks you Seamster. This project was another labor of love.
http://www.instructables.com/id/Mini-Cadillac-Body/