'81 GS450L Cafe Project

[spyug]

The easiest and best method in my mind is to glass over the foam "buck" with glass cloth and epoxy resin if you want a permanent base for multiple reproductions.

As mentioned it is a bit more expensive than using the polyester resin but cheap enough if you want to do it right for the future and multiple reuses.

One the epoxy hardens you can glass over with polyester resins with not difficulty.

The big thing to note is that once the buck is complete the surface is as smooth as you can get it. If it has any dimples or divots the layered glass/cloth ( for your molded seat) will stick to it. Smooth it and paint it so nothing can stick to it.

Hope this helps.

cheers,
Spyug

 

[gjohnson]

Absolutely, thanks for the advice guys. I took the weekend off to have some fun while a friend was in town. I should have some more pictures of progress up tonight

It will probably be best to use this "buck" to make a female mold that I can take multiples from? I am also toying with the idea of wrapping the entire piece of foam in fiberglass to make it all one solid piece. The only problem is, I was planning on hiding some of the electronics in the tail section to open up the battery storage area and give the bike a cleaner look. Decisions decisions.

 

[Hoosier Daddy]

I have seen removable pads (velcro) with a trap door or opening at the bum stop that allows access into the hump for that...
Just sayin.

 

[gjohnson]

I am thinking that is the way to go as well, maybe put the trap door on the bottom of it I can remove a couple of bolts and have the top cover come off completely and still have a fiberglass seat pan, Kind of hard to explain ill draw a visualization in a bit.

 

[gjohnson]

Here's a quick sketch of what I have planned, any feedback on my idea would be great. the bottom panel will slide into the top cover and then be held in place by 6 bolts with metal guiding sleeves, I plan on using washers inside of the fiber glass to reinforce it. I just don't know if the seat will be strong enough? Under the seat section I might have to build some supports.

Don't mind my chicken scratch lol.

 

[Hoosier Daddy]

So what is your reasoning for "wrapping the entire piece of foam in fiberglass to make it all one solid piece." ? Seems like a lot of unnessecary work to me, but you may have something in mind.

 

[gjohnson]

I was thinking of different ways to do it. If the entire piece of foam was wrapped it would have a hard time flexing/cracking, but I couldn't move the battery into the rear bump.

 

[gjohnson]

Whew, just finished 3 layers of fiberglass. Lets hope it turns out!

 

[verde]

Whew, just finished 3 layers of fiberglass. Lets hope it turns out!

Guess I'm just a little late to chime in! Did a battery box and seat pan out of fiberglass on my triumph. Foil tape for the base of the pan was worth the extra cost, much easier to work with than kitchen foil, especially on the vertical sections and what not. Something you could still do if you want: For anchor points, I glassed in t-nuts. Just gotta leave a bolt in when you do it to keep the threads clear. Might work well for your cocktail napkin sketch 2-piece idea. My seat build: http://www.youtube.com/watch?v=Q14K_sny5YQ

 

[gjohnson]

Very cool video, thanks for posting it up.

 

[Adler]

Guess I'm just a little late to chime in! Did a battery box and seat pan out of fiberglass on my triumph. Foil tape for the base of the pan was worth the extra cost, much easier to work with than kitchen foil, especially on the vertical sections and what not. Something you could still do if you want: For anchor points, I glassed in t-nuts. Just gotta leave a bolt in when you do it to keep the threads clear. Might work well for your cocktail napkin sketch 2-piece idea. My seat build: http://www.youtube.com/watch?v=Q14K_sny5YQ

That's hot...

 

[Mop Bucket]

Did it turn out? Lets see some pictures.

 

[gjohnson]

I am going to check it tonight when I get home. I took spyug's advice and just wrapped it in tape then glassed over the top. The poly resin was so smelly/messy, I am thinking for the bottom seat pan I am going to stop by the fiberglass store and pickup some epoxy resin.

I should be home around 5 and I'll take some pictures

 

[gjohnson]

Okay I didn't get any pictures while laying the fiberglass because it was messy and I wasn't about to grab my Canon DSLR with resin all over me lol.

Here's a picture of it taped up prior to glassing:

After glassing, I should have done at least twice as many layers. I am going to pickup some epoxy resin and try to add more to the inside. Also it will be cut down about 1/2 an inch.

Cutting the mold out of it... it was pretty stubborn. lol don't worry I cleaned the floor up before the wife to be got home...

Mold is out of it, just needs more layers bondo, sand, bondo, sand....

I couldn't resist throwing it on the bike real quick, imagine it cut down about 1/2 - 3/4 of an inch.

 

[Flaming Chainsaws]

Looking good! Way to start out the project! Any plans on changing the gas tank out?

 

[gjohnson]

absolutely, I would like one that is not quite so tear dropped shaped, with some knee dents.

 

[Hoosier Daddy]

NICE JOB... see that wasn't so bad. by the time you get the seat pad and cover on the hump won't look so big. How well did the duct tape release from the Glass?

 

[SVSooke]

Very nice.Like the 03 SV in pic 3 to.

 

[gjohnson]

The glass pulled away from the duct tape pretty easily, i just slid a screw driver around the edges, then pulled the seat part out. once that was out of the way i just carved a handle in the foam to grab a hold of and gave it a few pulls. Took maybe 15 minutes to get the mold out.

SvSooke - Thanks, that's my '03 SV1K, I love it and I need to do some fiberglass repair on the left fairing... maybe when the cafe is done.

 

[Mop Bucket]

Nice, thanks for the pics.