Fiberglass

[That1Guy]

I know what you guys are thinking right now, "oh boy another fiberglass thread" but I think this is different than the other fiberglass discussions we have had here.

I am thinking about making some "pre-runner" style fiberglass fenders, the problem is, there isn't much info on the net on actual fenders. So I was hoping to maybe get some advice or maybe some links you guys may have come across. Pretty much what I am going for is a 2-3 inch bulge to take the place of the original steel fender and also give more clearance and a better look than the "flares".

From the searching I have done I gather this will be my plan of attack.

1) basically lay some spray foam over the existing fender in the shape/thickness I am shooting for
2) once smoothed oout make a skin over that which will be my mold
3) remove that skin
4) on the inside of that (keeping roughly the original mounting points and body lines) lay approximately 7 layers of fiber/resin
5) remove from mold
6) sand smooth
7) drill out the mounting holes

I know there is alot more including steps to make sure your pieces dont stick together but this is the general idea. Has anyone here dabbled with fiberglass? Got any tips? If they come out OK and the molds are also OK I would not be opposed to making more sets either if anyone is interested.

[mikepeters1983]

If you can do this and make more you can count me in for a set. Be nice to have the extra stuff. Do you know how wide you are thinking of making them yet?

[That1Guy]

If you can do this and make more you can count me in for a set. Be nice to have the extra stuff. Do you know how wide you are thinking of making them yet?

Im thinking about 3 inches. I will wait until I get my spacers though to figure that part out. I would like for it to go out just past the wheels.

[mikepeters1983]

Thats understandable, I aint got no clue yet as to how far my tires are going to stick out. I got to wait till I am least hit IN before I will know on mine for sure. But 3in is better then nothing to. You got any plans while you \are at it on trying to do something for the rear yet?

[SteveTB03]

I like the idea and itd be cool to see this.

But have you thought of just cutting your fenders do a trim job so they dont hit??

[mikepeters1983]

Well most likely i have all ready planed to cut the front and rear fenders so when at full stuff I wont hit and rub anything. I got the room to do it on the front and back, plus it might makes some things easier for me till I can get the new RCA's and panhand bar.

[Rob93]

I've always toyed with this idea, fiberglass is pretty fun to work with... I just don't know of how to do the rear with the door in the way, and i think it looks funky with oversized fender in only the front.
There's a pretty good thread with a bronco2 somewhere on google, I'll try and find it later

[mikepeters1983]

i think it looks funky with oversized fender in only the front.

and thats why I drive a EXT

[Hpimichael02]

good idea, cant wait to see some progress, im gonna do it with trailer fender well tubs and weld em on but fiber glass is a nicer option though, must be atleast 5-7 layers thicks though

[That1Guy]

I like the idea and itd be cool to see this.

But have you thought of just cutting your fenders do a trim job so they dont hit??

I have thought about it but in California the tires are supposed to be covered and honestly I am not a fan of tthe flexible screw/stick on flares. This will be a pretty big project but I think it will be fun.

I do have an idea for the rear but I have yet to come up with something I could make functional for anything other than covering the tires. My idea is kind of like what they do with the 4 door explorers. Need to pull out the lawn chair and stair at it for a couple hours most likely and talk to someone who has done something similar.

[Rob93]

How are you going to make the part of the door? Make an entire new door? That seems like too much for me. I guess you could make it come out with some foam and glass over it and possibly a thin layer of bondo to make it flow into the door, you would just have to repaint the entire door after

[That1Guy]

How are you going to make the part of the door? Make an entire new door? That seems like too much for me. I guess you could make it come out with some foam and glass over it and possibly a thin layer of bondo to make it flow into the door, you would just have to repaint the entire door after

Thats how the explorer is. The whole door is still there, they just used the expanding foam and shape how they want then make a mold off that. Like I said though, that is just an idea for the rear and I dont even know if it will be possible. Im going to start with one front and see if I can even do it.

[Rob93]

How are you going to make the part of the door? Make an entire new door? That seems like too much for me. I guess you could make it come out with some foam and glass over it and possibly a thin layer of bondo to make it flow into the door, you would just have to repaint the entire door after

Thats how the explorer is. The whole door is still there, they just used the expanding foam and shape how they want then make a mold off that. Like I said though, that is just an idea for the rear and I dont even know if it will be possible. Im going to start with one front and see if I can even do it.

I was thinking more of a bolt on flare, but this thread is more about an entire fender. I might make up some templates and use the leftover glass from my boat and see what I come up with. Almost all the supplies I already have, so I might give it a try

[OregTrailBlazin]

I've done fiberglass... Used to travel during the summer with my dad while he worked. Stayed next to a guy that was building an Airplane in his garage, helped him all day while my dad worked. Was one of the best summers I've had

You've got the exact idea!!.. I generally use the pink construction foam, it is more chemical resistant and easier to seal and smooth.

Like you said:

1) Spray the fender with foam, and stick on Pink construction foam.
2) Carve and shape... Use bondo to fill and finish it like it was about to be painted. (The smoother and nicer you make this the less work in the future.)
3) Apply release agent, and apply resin/fiberglass.. MAKE sure to add some ribs, and support so when you pull it off it can't break or flex.
4) Peel it off and you have a Negative of the fender skin. Most of the tabs and bolt mounts are added after the skin is made...

As you said, there is allot of stuff inbetween, but all it takes is practice and time.. Working with Fiberglass is pretty cheap, just VERY time consuming.

[Mooseknuckle]

A very cool idea I would like to see it myself.

[That1Guy]

I've done fiberglass... Used to travel during the summer with my dad while he worked. Stayed next to a guy that was building an Airplane in his garage, helped him all day while my dad worked. Was one of the best summers I've had

You've got the exact idea!!.. I generally use the pink construction foam, it is more chemical resistant and easier to seal and smooth.

Like you said:

1) Spray the fender with foam, and stick on Pink construction foam.
2) Carve and shape... Use bondo to fill and finish it like it was about to be painted. (The smoother and nicer you make this the less work in the future.)
3) Apply release agent, and apply resin/fiberglass.. MAKE sure to add some ribs, and support so when you pull it off it can't break or flex.
4) Peel it off and you have a Negative of the fender skin. Most of the tabs and bolt mounts are added after the skin is made...

As you said, there is allot of stuff inbetween, but all it takes is practice and time.. Working with Fiberglass is pretty cheap, just VERY time consuming.

Thank you for the tips! And this pink construction foam, is there any different name? I cant find it. And also I plan on doing the majority of the shaping with the fender on the vehicle, how do I get the expanding foam to stick to the fender and not fall off?

[OregTrailBlazin]

Thank you for the tips! And this pink construction foam, is there any different name? I cant find it. And also I plan on doing the majority of the shaping with the fender on the vehicle, how do I get the expanding foam to stick to the fender and not fall off?

Hmmm... took me awhile to find that one. Foam board insulation. The foam is actually called -Extruded Polystyrene Foam- comes in Pink and Blue. They will have it at your local Home Depot.

I would shape it on the truck too, the spray expanding foam should have no problem sticking to it, but you will probably not get it off. You could just hot glue the Polystyrene Foam to the truck that way you can peel it when your done.

Everything I've built has been completely from scratch, we usually glue and pin the foam together then cut and shape to the desired design... Doing it off the truck would be completely new to me.. I would love to give it a shot though, it would be sweet to have a full piece fiberglass front-end.

[That1Guy]

Thank you for the tips! And this pink construction foam, is there any different name? I cant find it. And also I plan on doing the majority of the shaping with the fender on the vehicle, how do I get the expanding foam to stick to the fender and not fall off?

Hmmm... took me awhile to find that one. Foam board insulation. The foam is actually called -Extruded Polystyrene Foam- comes in Pink and Blue. They will have it at your local Home Depot.

I would shape it on the truck too, the spray expanding foam should have no problem sticking to it, but you will probably not get it off. You could just hot glue the Polystyrene Foam to the truck that way you can peel it when your done.

Everything I've built has been completely from scratch, we usually glue and pin the foam together then cut and shape to the desired design... Doing it off the truck would be completely new to me.. I would love to give it a shot though, it would be sweet to have a full piece fiberglass front-end.

Hmm. I think I will just lay a couple layers of foil down and go to town over that.

Heres my inspiration thread.
http://www.dezertrangers.com/vb/fab-shop/119816.htm

[OregTrailBlazin]

Hmm. I think I will just lay a couple layers of foil down and go to town over that.

Heres my inspiration thread.
http://www.dezertrangers.com/vb/fab-shop/119816.htm

Awesome thread!!.. Great inspiration, almost make me want to give it a shot!!

With how easy it is to pull our fenders off, I would probably do that, so you can get it matched right down to the hood and door without sanding too much of the original paint.

[That1Guy]

Hmm. I think I will just lay a couple layers of foil down and go to town over that.

Heres my inspiration thread.
http://www.dezertrangers.com/vb/fab-shop/119816.htm

Awesome thread!!.. Great inspiration, almost make me want to give it a shot!!

With how easy it is to pull our fenders off, I would probably do that, so you can get it matched right down to the hood and door without sanding too much of the original paint.

Another good thread right here.

http://www.dezertrangers.com/vb/fab-shop/74366.htm

So your thinking I should do it this way?