How to Make Car Body Kit Mould

A body kit is a set of aftermarket parts that are added to a car to improve its appearance and aerodynamics. Body kits can be made from a variety of materials, including fiberglass, carbon fiber, and polyurethane. Fiberglass is the most common material used for body kits, as it is relatively inexpensive and easy to work with.

Making a body kit mould is a complex and time-consuming process, but it can be done at home with the right tools and materials. Here is a step-by-step guide on how to make a car body kit mould:

Materials

• Fiberglass cloth
• Fiberglass resin
• Hardener
• Mould release wax
• Polyethylene sheeting
• Scissors
• Sandpaper
• Putty knife
• Bondo
• Primer
• Paint

Tools

• Angle grinder
• Drill
• Jigsaw
• Sander
• Vacuum cleaner
• Spray gun

Step 1: Prepare the Car

The first step is to prepare the car for the mould. This involves removing all of the body panels that will be covered by the body kit. Once the body panels are removed, the car should be washed and waxed to remove any dirt or debris.

Step 2: Create a Plug

The next step is to create a plug. The plug is a temporary form that will be used to create the mould. The plug can be made from a variety of materials, including wood, foam, or clay. Once the plug is created, it should be sanded and primed to create a smooth surface.

Step 3: Apply Mould Release Wax

Once the plug is prepared, it should be coated with mould release wax. Mould release wax prevents the fiberglass from sticking to the plug. The wax should be applied evenly to the entire surface of the plug.

Step 4: Cover the Plug with Polyethylene Sheeting

Once the mould release wax has been applied, the plug should be covered with polyethylene sheeting. The polyethylene sheeting will help to create a smooth surface on the mould.

Step 5: Lay Up the Fiberglass

The next step is to lay up the fiberglass. Fiberglass is a woven fabric that is made from glass fibers. The fiberglass should be cut into pieces that are large enough to cover the plug. The fiberglass should be laid up in layers, with each layer being saturated with fiberglass resin. The resin should be mixed with hardener according to the manufacturer’s instructions.

Step 6: Cure the Fiberglass

Once the fiberglass has been laid up, it should be allowed to cure. The curing process can take several hours or even days, depending on the temperature and humidity. Once the fiberglass has cured, it should be removed from the plug.

Step 7: Finish the Mould

Once the fiberglass has been removed from the plug, it should be finished. The mould should be sanded and primed to create a smooth surface. The mould should also be reinforced with bondo to make it more durable.

Step 8: Make the Body Kit

Once the mould is finished, it can be used to make the body kit. The body kit can be made from a variety of materials, including fiberglass, carbon fiber, and polyurethane. The material that is used will depend on the desired look and performance of the body kit.

Step 9: Install the Body Kit

Once the body kit is made, it can be installed on the car. The body kit should be installed according to the manufacturer’s instructions. Once the body kit is installed, the car should be repainted to match the rest of the car.

Conclusion

Making a car body kit mould is a complex and time-consuming process, but it can be done at home with the right tools and materials. By following the steps in this guide, you can create a high-quality body kit that will improve the appearance and aerodynamics of your car.