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Tutorial DIY Polyester Cockpit

Discussion in 'DIY peripherals' started by pitstopp, May 22, 2013.

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  1. pitstopp

    pitstopp Active Member

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    Here is a short Tutorial how to make a Cockpit (or any other Case, etc.) from Polyster fiber.

    First Step: We need a mold, here is shown how easy you can make a cheap lost mold.
    IMG_5087.JPG
    I took a block of Styropor an shaped out the form with a knife and a grater.
    The Surface should be smooth and symmetric.

    IMG_5091.JPG
    The Form of my Cockpit is a litlle bit to complex for a mold in one piece, so I had to split it.
    For a bigger form you can glue the Styropor togther with a special glue.

    IMG_5093.JPG
    Then you must cover the complete mold with wallpaper glue and newspaper.
    Cause the Polyester resin would dissolve the Styropor. If you use Styrodur you can skip this step . Styrodur is resistant, but much more expansive.

    IMG_5102.JPG
    Everything ready to laminate !
    Cut out some Fiberpeaces that fit the place you want to start.
    Saturate the mold and the Fiber and put the fiber in place.
    Then push out the air under the fiber with a short Hair Paintbrush.
    That is important for stability reasons.

    WARNING: Don`t mix more than 500g of Resin, the resin will get stuck in less than 20 min!

    IMG_5105.JPG
    Work in Progress!

    IMG_5108.JPG
    First Part is finished!

    IMG_5129.JPG
    Here the Parts for the Midle of the Cockpit

    IMG_5130.JPG
    Every thing fits together

    IMG_5132.JPG
    Cut off the outer edges and make everything ready for glueing together.
    Have an eye if it is symetric!

    IMG_5135.JPG
    you need special fiber-reinforced glue!

    IMG_5141.JPG
    First test, not too bad!

    IMG_5156.JPG
    You have to fill the surface for a perfect paint

    IMG_8489.jpg
    IMG_85052.jpg

    This is only a short Tutorial, there ar a lot of Videos on YT. Key words: Doorbords, RC Plane Body

    For a first attempt this is possible to difficult.
    Try to make a Button Box, You can use your Girlfriends Tupperbox as a positiv mold!
    It is really easy to get good results and it is not more expansive than Metal or wood .
    Find out a company those who make car Tuning Body work or RC Planes.
    Speak to your local Car Painter for hints!
    If you have found a company they will supply you with every thing you need !

    Thanks for your attention
    Kai
    • Like Like x 14
    • Informative Informative x 1
    pitstopp, May 22, 2013
    #1
  2. value1

    value1 Nerd SimAxe Beta Tester SimTools Developer Gold Contributor

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    :clap: Beautiful! Nicely made! :clap:
    value1, May 22, 2013
    #2
  3. eaorobbie

    eaorobbie Well-Known Member SimTools Developer Gold Contributor

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    Very nice always wanted something a long those lines, really looks great and all, done a button box before but never thought of using foam to create the mold, love the idea of newspaper to cover mmmm feel a mod coming on. Bugger

    Thanks for the information very informative.
    eaorobbie, May 23, 2013
    #3
  4. pitstopp

    pitstopp Active Member

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    Here some Pics of my first Cockpit.
    These is really easy to make, costs arround 50€ and takes 3-4 hours .

    IMG_9794.JPG

    Mold is an laundry Box (negativ).
    only put some molding wax in, as Formula 5, coating with gelcoat and 2-3 layer of poyester Fiber.
    The Frontpanel is made on a glasspanel to get an perfect flat surface.
    cut it out, glue it together, abrade the edges an give it a paint with the spray can.

    IMG_7332.JPG


    If you want a bigger Project , check this out
    diy-polyester-roof-t3473.html?hilit=polyester%20roof

    Best Regards
    Kai
    • Like Like x 1
    pitstopp, May 23, 2013
    #4
  5. eaorobbie

    eaorobbie Well-Known Member SimTools Developer Gold Contributor

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    My Motion Simulator:
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    I like the idea, a nice way to really give that professional touch.
    My whole sim is 2 PVC seat Mover and you giving me ideas....
    Feel the need to mod ......
    Cheers
    eaorobbie, May 23, 2013
    #5
  6. bsft

    bsft

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    nice job
    bsft, May 23, 2013
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  7. ferslash

    ferslash Active Member

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    nice!

    how did you painted the orange one? profesional air compressor? like a car?
    ferslash, Jun 4, 2013
    #7
  8. RaceRay

    RaceRay Administrator Staff Member SimAxe Beta Tester

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    Wow awesome job. I am also interested in your paintjob. Looks very professional. Did you paint it at a paintshop?
    RaceRay, Jun 4, 2013
    #8
  9. pitstopp

    pitstopp Active Member

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    Hi

    I used a proffesional Spray Gun and a Compressor for the orange car paint.
    For the Black Stripes i used a Spraycan.
    pitstopp, Jun 4, 2013
    #9
  10. mario318i

    mario318i New Member

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    LOVE it
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  11. Historiker

    Historiker Dramamine Adict Gold Contributor

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    Wow, impressive!
    Historiker, Jul 3, 2013
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  12. RacingMat

    RacingMat Well-Known Member Gold Contributor

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    Very good tutorial, pitstopp ! Thks

    Are fiber glass rolls (used for being glued and coated on walls) suitable for that ?
    RacingMat, Jul 31, 2013
    #12
  13. pitstopp

    pitstopp Active Member

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    Hallo

    no Fiberglass for walls is a totally diffrent product. I think it is only called Fiber Glass and has nothing to do with Fiber glass for Molds and modelling Parts.
    pitstopp, Jul 31, 2013
    #13
  14. RacingMat

    RacingMat Well-Known Member Gold Contributor

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    RacingMat, Jul 31, 2013
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  15. pitstopp

    pitstopp Active Member

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    Hi Mat,

    i think this offer is OK. Shipping costs are a little bit expansive, mhhh.

    I hope you keep us informed about the progress of your work :)

    Regards
    Kai
    pitstopp, Aug 1, 2013
    #15
  16. eaorobbie

    eaorobbie Well-Known Member SimTools Developer Gold Contributor

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    Shipping cost is properly due to the transport of hazardous goods (resin).
    eaorobbie, Aug 1, 2013
    #16
  17. ericRacer

    ericRacer You get old because you stop playing ! Gold Contributor

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    Wow, impressive ! :thumbs thank you for sharing your work :cheers
    ericRacer, Nov 24, 2013
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  18. Albertus

    Albertus New Member

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    I was wondering how they make fiberglass dashes! thanx man! Learned allot!
    Albertus, Mar 11, 2014
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  19. Nath Older

    Nath Older Member

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    This looks awsome. well done.
    Nath Older, Mar 17, 2014
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  20. shannonb1

    shannonb1 Well-Known Member

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    thats is the coolest sh%t Ive seen in a while. I must steal this now!
    shannonb1, Apr 4, 2014
    #20
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