How to make a spoiler from Foam, Clay, Fiberglass, Poly-Urethane - StealthBuilt Audi A6 C6
HTML-код
- Опубликовано: 21 авг 2024
- A quick how it was made video of the design and build process of the StealthBuilt Audi A6 c6 DuckTail Spoiler from Foam, Clay, Fiberglass and Poly-urethane plastic. By Kimmel Fabrication Studio LLC.
Follow our build as we take a stock 2006 Audi A6 and turn it into a wide body beast!
A huge thanks to our Sponsor Chavant Clay and the entire Kimmel Fabrication Team who helped build this spoiler and video series!
Follow our Channel for more "how to" and "build" videos!
www.kimmelfab.com
Kimmel Fabrication Studio LLC
By Sam Kimmel - KFS
I’ve watched this video multiple times and your care and attention to detail is phenomenal.
Much appreciated! We have tried to get even better on our recent videos!
amazing video. I always say quality over quantity and it definitely look like you guys made sure a lot of work went into making this! would love to see a thorough DIY video explaining steps, tools and materials used to making any exterior body modification in the near future!
king2468 we are trying to make more informative diy videos as we go. Be sure to check out our newer widebody build videos!!
damn cuh shoutout hooziers
Good job awesome 👏🏻
THANKS!
Amazing job! Keep up the great work!
TheGhettoAgent Thank you!
Nice video but it would be nicer to talk about what your doing instead of playing some stupid House song.
Bob Owen ok.
you're=you are
If u have a better knowledge of cars u don't need to be asking. Just by looking.. i know its an audi a6
@@bitsurfer0101 uR gay
Isn't much of a "how to" as it is a "watch the build" video. A voice over explaining everything thats going on would be much more useful. Thanks for posting anyways.
Hey guys, what was the purpose of the "rotary cast part"? Was the completed fiberglass piece pulled from the mold not good enough for mounting? Or did you cast the second piece from Urethane? Just tooling around with ideas for my fabrication and assumed Plug-Mold-Fiberglass was good enough. If you did use poly - why? Durability? I HAVE SO MANY QUESTIONS, but I really appreciate the video!
We make parts to resell.
Good work!
Well that was impressive
my67falcon Thanks!
cool so whens the duck tail for the W211 E55 amg coming out ?? 😬😬👍
Dude... what a great job! Incredible!!! A question, at 0:42 minutes, what are those little plaques embedded in the spoiler and its purpose? And how did you make them fit perfectly in the spoiler?
I’ve watched this video like 5 times and I want to attempt it but there’s some products you’re using that I’m not familiar with. What is PVA? What is the white gel coat? What silicone are you using for the molds? So many questions. This is very inspiring
All of these products can be bought online. I am not affiliated with any business selling these products, but you can check ones like CompositeEnvisions.com or Fibreglast.com
Kimmel Fabrication Studio LLC thanks for the quick reply and the links! I think I’ve got some shopping to do. Keep up the great work you earned your sub!
so cool, thank you! this will help alot on my one off dart body kit im going to make 😁
good job!
Doc.Cali Thank you!
Hey man got a couple questions. 1. What's your wait times in between pva/gel/ resin? Do you let fully dry? 2. Is there a difference between the orange and white gel coats you're using? Or could you use one for the both?
I apply the PVA once it is dry to the touch you can apply the gelcoat. When the gelcoat is tacky, but does not come off on your finger when you touch it, it is ready for resin. I hope that helps! - Sam K.
looks great made in Indiana too
Heck yea!
I still don't know what the final wing is made of. We end with the finished mould and the end product but we didn't see the part being cast into the mould (or did we). Without narration I'm a bit unsure here and there. The title description mentions Poly-urethane plastic - so I suppose it's that?? I really want to copy this technique but don't have the last part of the puzzle without knowing - please reply. Thanks
We used a pour cast poly-urethane. The mold was placed in a random rotational casting machine we built, filled with liquid poly-urethane and rotated until cured and a hollow cast part was produced.
I need to do this but im not quite sure whats going on still what type of foam was used? What happend between the fins you put on and the next part? Howd u make the fins sit perfectly with that part? Im trying to make bumper canards
Very nice work. How did you close the surface on the underside and at the ends, (on trunk part of wing)
After we finished the top side we removed it from the trunk. taped off the trunk where the spoiler is located, laid a thin layer of fiberglass right to the trunk and while it was still wet, pressed the top portion of the spoiler into / onto it until it hardened. This gave a perfect fitting lower portion.
Thank you.
Kimmel Fabrication Studio LLC how did the foil duct tape assist in this part of the build? does it help with release of the underside fiberglass you mentioned above? also, when you lay up the thin fiberglass straight onto the trunk, do you use PVA AND gel coat before laying the fiberglass like you did when making your "positive"? the wet fiberglass adhered okay to the already dry spoiler?
Mark Joseph think they are making templates to close in the bottom of the spoiler. They seem to have missed out what they did after that but they ended up with a solid piece to make the molds with.
Mark Joseph We layered the metal tape over the masking tape for a smoother release of the fiberglass from the car. With the hollow bottomed spoiler removed from the trunk we put down a few layers of fiberglass mat and resin, while it was still wet, we put the hollow bottomed spoiler back onto the trunk using pressure to hold it into the wet fiberglass until it cured. We then removed the piece from the trunk, at this time it now had a bottom, the "flashing" was sanded off and end caps were glassed onto it and we had a totally enclosed shape.
When will post more content?
Soon, make sure to subscribe! You can also see our projects daily on Instagram @kimmelfab
How much clay did you use. I’m trying to make rear bumper ends or side skirts if you will. They are selling moldable clay by the grams(300 grams in a bucket)
I'm not exactly sure how much clay I used on this project. A cheap alternative to special modeling clay is just simple pottery clay. If you are doing the entire clay project in a day or so, you can use pottery clay, just keep it moistened.
Are you directly laying the fiberglass on top of the chavant clay? Are that not broke the clay and make it can not be use anymore?
Layed over PVA
Hi, Currently I have Polyester Resin, Polyurethane Spray foam, Fiberglass mat/cloth, and Auto body polyester filler. I plan to use the polyurethane spray foam and mold/trim it for a car moulding.
1. Can I directly apply the polyester resin and fiberglass mat on the trimmed foam mold then apply the auto body filler after?
2. Can the auto body filler be applied directly to the foam mold?
Thanks!
You should be able to apply the auto body filler to the foam with no problems. Applying resin to the foam depends on what type of foam you have. Some foam will melt when polyester resin is applied.
I would suggest testing a small piece first.
So what kind of foam should you use then
How’s the C6 coming fellas 😉!?
Starting over with a completely new (crazy) build for it! Stay tuned! Subscribe! ;)
@@kimmelfab say less 👊🏾
Amazing work, im doing the same on my malibu 2008, can please tell me what materials did you use to make the molds?
Thank you! We use tooling Gelcoat and tooling resin with fiberglass mat.
@@kimmelfab thank you very much! Keep with the amazing work
Is there a way to make a symmetrical mold with the ends of each side of the duck tail is it possible to just turn the mold inside out or is there something else to do to make the one side like the other if you already showed it in the video would you be able to elaborate?
He uses those little numbered pieces of paper and spaces them evenly, after that it's a big connect the dots to get it looking awesome.
can you do this for my Hyundai Tiburon 2008
nice.
Thank you!
Teach me how to make a girl friend out of fiber glass and silicone. We will use the fiber glass for the skeleton.
LastRideYZF I wish I could lol!
Do you have to wait between layers of resin and fiberglass? If so, how much time? Thank you!
You do not absolutely have to wait, but I typically wait for it to kick and begin cooling down before adding more layers to prevent overheating the resin.
@@kimmelfab Thanks! And do you need a special compact foam for this kind of job? What's the exact name of this foam?
@@jeremiebeaulieu8495 The foam used in this video was industrial roof insulation board. It can be found at most commercial supply companies. Truthfully any foam can work, you just have to protect the foam from resin, as it can dissolve some foam.
@@kimmelfab Thank you! Very helpful!
Does the hardness of the clay matter for fiberglass? (Soft, medium, hard)
The hardness matters when you shape the clay or when you lay anything over the top of the clay that can deform it during the process.
I wouldn't recommend soft, probably a medium to hard, but keep in mind that these Clay's need warmed in an oven in order to be "pushed into position" on the car from their initial block form. Once the clay is cooled you can carve it.
So many steps to make just one spoiler?
Hey guys what was the silver tape for when you traced the outline of the spoiler? Also for the PVA is that just to seal the clay so you can fibgerglass over it?
The silver tape is a metal tape and is used because nothing will stick to it and I like how it conforms to parts. The PVA is used so to seal the clay indeed. We reuse some of the clay and this makes it so it isn't ruined in the casting process. Thanks for watching!
Awesome!! thanks for the great video, and replying so fast! Subscribed.
you should sell the molds u would be rich as hell if it was c5 s6 i would buy
Send the cash!
Curious how you cast the part; did you use a giant rotary casting machine or is there a way to do it manually?
We built a custom rotary casting machine. I'm sure it could be done manually but I'm not sure it would be very consistent if done that way.
@@kimmelfab thanks for the quick reply!
@@garymatteau776 Thanks for watching!
@@kimmelfab just spitballing ways to fabricate a NLA spoiler for a Scirocco, this process looks promising but I wonder how well rotary casting will work with a long thin item. It needs to be one piece across the top of the hatch
@@garymatteau776 Honestly, I'd suggest fiberglass. We made a few of these rotary cast parts, but found that the poly-urethane had to be thicker than we wanted to be worthy enough to be useful. That made it difficult to match the weight of a fiberglass part, so in the end we made these in fiberglass.
Ill buy one...if u have a ducktail for the audi a4 1.8t b6 quattro.. no ones got one
We dont currently make these for the A4, but you could always create one similarly! Thanks for watching!
I'm looking make a one time body kit or spoiler. If I follow your steps, do I stop at 5:18? The rest of your video is just showing to make a mold right?
jksp33 Yes, if you stop at 5:18 you have yourself a ready to paint "1 off" piece.
Awesome. Thanx! :)
jksp33 If you make a spoiler be sure to record and send me a link! ;)
Maybe not a spoiler, but was thinking of some canards as a start, then a front lip or side skirts. Will do, thanx.
this video is as at least necessary as the spoiler on a car...
Awesome thanks
what density foam did you use? how much clay did you use to mold it?
John Hammon There are lots of different foams you can use that do not melt from fiberglass resin, many are pretty expensive. I have found a foam, that I normally use from a supply house for industrial building roofs. it comes 4" thick and in a 4x8 foot sheet. You have to cut and stack layers of it if you need to carve something thicker than 4" but it generally works well for our purpose. It is a high density open cell foam that carves and sands very well.
John Hammon I think we used 2 bricks (4lb each) of Chavant Autostyle Clay. We then carved much of it away, probably had 2lb on it in the end before we made the mold. It is much easier and quicker and less dirty to use clay than "bondo" for shaping the final finish.
Can you make a videos showing how you cast inside the two part silicone mold? Or email me?
Email me sam@stealthbuilt.com
Where is the finished car
I wish it were finished, but we stripped it down. Ready to start a new, more interesting build!
what the materials are again guys?
What did you use for silicone and casting resin? Im working on a similar project.
Hi Bryan, we used Smooth-On brand Smooth Cast 65D resin and Platinum Silicon. Thanks for watching!
Thanks for the quick response and great work on the spoiler! Did you get the platinum silicone from smooth-on as well? How many pulls can you get from each silicone mold before it starts deteriorating. I'm working on reproducing a spoiler that is no longer made and I'm hoping to make 20+ spoilers and I'm hoping to not have to remake molds.
+Bryan Brown Platinum silicone should last quite a while, definitely 20 spoilers if you treat it nice. You can also use a release agent (I dont with silicon) I buy my smooth on products from Reynolds Advanced Materials, they are a dealer and closest to my location to reduce shipping cost. You might email smooth on for a dealer near you.
Which platinum silicone did you use? Also, how much silicone did it take to make all of the molds?
gostei
please make a tutorial on how to make a spoiler from foam without speeding up the video
tyger I would love to do another video, I'll try to be more informative, as I am in some of our other videos!
i would appreciate it
... fuck that I'm using paper mache
What did you use to cast the real spoiler?
White Madness Garage Hey, we used a special poly-urethane for rotary casting. Thanks for watching!
what material did you use for the final casting?
Polyurethane
Polyurethan resin? Will it not crack?
@@MaTeOpl95 this resin was made specifically for rotary casting applications.
Can you make me a custom spoiler pleeeease, they wanna charge 450 for a jdm spoiler that looks basic and unattractive, rather pay that amount to someone for something custom
Where are you located?
@@kimmelfab houston texas
@@homelackin2234 now that is a drive!
@@kimmelfab where are you?
Fort Wayne, indiana
the music was tight xD
Makes it look easy 😐
It's not all that bad!
What kind of pva was it
You can use any PVA.
Is this a 2005?
2006 A6 S-line
Came here to see how to do this on my '08 Audi A4😂😂😂
Was I able to help?
isn't that an Audi A6 4f and no C6
2006 Audi A6 4.2 Quattro C6 Body 4f S-line version.
isn't this fwd ?
AWD 4.2V8
lol, good first effort though.
Thanks Jack. We build this sort of thing all the time.
@@kimmelfab you should have laid the pva and fiberglass on the trunk first before adding the foam / clay, why don't you have the spoiler on your website for sale anymore? did you mold deform?
@@bukakejack2985 I didnt put pva on the trunk because tape doesn't stay attached to PVA. The parts aren't on my website because I no longer sell them. Thanks for your input.
Go and buy from online instead
Great idea, thanks!
Alus gening gan
Wasn't your Mom mad when she saw what you did to her kitchen counter?
geraldfelthammer LOL, it's my house
I not explaining it smh
Sorry that it didnt help you.
@@kimmelfab 🤦♂️🤦♂️
I'll try to make my next free help video suite your needs better.
song?
Yes it was a bit
Ya spent more video time on applying tape, than finishing the plug. Start all over..
ThomasTheSailor Chubby ok, I'll do that...
Would have preferred some explanation instead of the mind numbing musak. Also want to see the finished wing.
I got a bit confused - we do see the final product, but not it being poured into the mould. Sorry if I was a bit unkind about the music above, but there were certain aspects that needed a bit of explanation for me. For example, it's not explained what the foil tape was for, I presume to make a bottom surface for the wing, but we don't see that, at 4:39 it just skips to the final shape.
I replied above. This video was made quite a few years ago when we were first getting started in video production so the quality of the video, music and even our portion are not on par with our current videos. Feel free to email me with questions and I will do my best to help! sales@kimmelfabricationstudio.com
this guys audi a6 red is nice monay. stock nice this is guys looser.