How to Make A Fiberglass Mold from a Plug - Part 1
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- Опубликовано: 20 авг 2024
- In this video series we will show you how to make a plug for a fiberglass mold. This technique can be used for just about anything that fits onto a table. You can use this knowledge to transfer to larger scaled jobs and with the very handy hot wire trick, you can cut and shape plugs of all sizes for all kinds of jobs.
Watch as Stephan shapes his motorcycle seat mold and clearly lays out the steps to creating your own plug. 
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Be sure to use Polystyrene foam when using a hot-wire cutter. If you cut Urethane foam (from craft store) with a hot-wire, burning urethane creates Cyanide gas, which is deadly. Good video!
This video was worth watching for the hot wire tension tip alone. Brilliant
1. he is running to hot, 2. he is cheating, he is only using one templet, if you want to be more precise you need to equal templets on each side of the foam :)
Done this b/4 back when kevlar first hit composite supply shops. Point plotted my own design racing canoe in sucessive stacked layers glued to each other layed out on a 30ft. weld/fitters ground flat precision slab. Sanded the foam steps between layers then used epoxy and kevlar inside an out. Ther are many ways to make molds and good old Home Depo foam works!
You mean carbon fiber? Kevlar is a full plastic--it's not composite.
If you put spring on one side of hotwire it will automatically stretch the wire and save you some nerves ;). i work with hotwire cutter every day and that simple mod helped a lot.
turnbuckle works as well
I used to cut model airplane wings, I put copper foil tape (the kind used on stained glass) to keep the wire from hanging up on the wood templates.
ruclips.net/video/LlV3lT4FK04/видео.html
Hey bud, great idea and video. For better control make the cutter stationary using a bench vice and work the form around the blade.
I've made several hot-wire foam cutters and even owned a CNC hot-wire cutter, but I never thought of using a guitar tuner for tensioning the wire. I always used a spring at one end to keep the tension as the wire heats up (a must-have IMO) but getting the tension just right was a pain. Using both a spring and the tuner would be perfect.
Never know which "part" to leave my comment(s) in :P
THANK YOU very very much for this lil "making molds from plugs" series, I got my 1st bondo/polyester-resins and fiberglass-resins (both, using poly as 'structure' with waterproof fiberglass-resin outers, when making small pieces) earlier **this month** so am very very green here but thanks to youtubes like yours here I have learned SO much so quickly and am having a blast with it, however I didn't know if I could 'get away' with using foam as a structure for detailed, small-size, 1-off creations (am not even using it 'as a plug' as you're detailing here, the foam will just stay in-place and be 'skeleton' because the piece I'm making can-be, in fact *is better-as*, a hollow piece instead of me trying to free-form mold Bondo and then glass over that which is what my method *would've* been if I didn't think "....go check youtube 1st" lol, and this was the 1st vid --- I love the web&video-sharing but gotta say this is a great example of *why* I mean I didn't have to go to other youtubers' takes on the same thing just your vid (well, vidS, since you split it up -- going for higher #'s that way I presume? naughty! ;) ) and am now ready to go outside and work instead of watching more vids / googling more!)
Thanks again, kickass video @TotalBoat am gonna 'scribe even though I probably don't need more glassing-instruction at this point (hmm maybe you have carbon-fiber work, that is my next 'venture' here!)
Fantastic video. Thanks, Stephan! For all those asking about the foam, Stephan clearly states that it's EPS (expanded polystyrene). I'm not sure if XPS (extruded polystyrene) would work the same. You can find pink Corning EPS in different thicknesses in the insulation aisle of Home Depot. At Lowes its colored green or blue. Glidden "gripper" primer paint works well to bond EPS. It's cheaper, more forgiving when lining the parts up, easier to clean up, and the fumes won't scramble your brains. Lots of videos on YT about cutting ad shaping and gluing EPS. EPS is really popular with RC drones builders and Halloween tombstones artists. Check out their vids, too.
Great suggestions in other comments about using a template on both sides of the plug and letting gravity do the work. Also an excellent suggestion to use a spring to keep tension on the wire. The suggestions to put the wire cutter in a vise and working the plug around it works okay with small pieces. But it's quite awkward with something this large. At least it is in my uncoordinated ants :-) Thanks to all for the input and questions. This is what community thinking is all about.
Putting templace inside mold to be sure you are cutting right is genius. Never thought about that.
Could have attached a small bubble level on the cutter to give you a better idea of level. Maybe it wouldn’t have helped much but this was very helpful for me. Thank you good sir
Easiest DIY Foam cutter here. Nice Job
I tune my cutter to an 'E' but a D still works. Does anyone have the TAB for this? But seriously... Lovely work, BRAVO I am going to now re-purpose all my old insulation off-cuts.
That was a Great Presentation! It was Clear & Short! Those two aspects are Very Valuable!
Put aluminum tape over the pink, then one layer of fiberglass over it, let harden and fill in perfections with body filler pull a plug from that
Thanks for the feedback!
Thanks, love the videos!
It will work with several D cell batteries too. Harbor freight sells (or did) one of these that is on a much smaller scale with a 6 inch wire cutter. In fact it looks like a coping saw which would be a good tool to repurpose. Hmmm.
Thank you I like this idea.
Best solution frend ❤❤❤❤
That was so satisfying to watch !!!
ruclips.net/video/LlV3lT4FK04/видео.html
@@usamafareed4786 What a dirtbag you are, just keep promoting the same stupid video for your business.
I understand it's pink panther foam just curious does,it matter if its,formula 250 or 150 r5 r2 I know there are diffrent types I'm just wondering will this change the results of making a mold this exact way you do this in all 4 videos cause I hear somevresin melts foam
Best cutting foam technique 👌
👏👏🙌🙌
great video
Thank you!!
Awesome video, I might use this method as we build our FSAE car next year!
ruclips.net/video/LlV3lT4FK04/видео.html
Holy shit this is EXACTLY what I was looking for! Thank you!
ruclips.net/video/LlV3lT4FK04/видео.html
@@usamafareed4786 What a dirtbag you are, just keep promoting the same stupid video for your business.
Best Video about models Resine show
Thank you!
I use an old electric carving knife.
No toxic fumes to inhale; no fire/burn hazard to be wary of.
hey, I really like your demonstration. What kind of glue do you use to glue the pink foam together?
That was 3M spray adhesive
I assume it was Super 77. 3M has a special spray for styrofoam. It is Spray 78.
What "KIND" of wire did you use? A guitar string? 316 steel or resistance wire?
A resistance wire
@@sailikith3576 Please, tell us more! What is a "RESISTANCE WIRE"? Where is one obtained?
@@BigFiveJack A Resistance wire is a type of wire that has high resistance in nature, that means when electricity is passed through the wire gets heated real fast and helps cutting the foam, The best one that is easily available is the *NICHROME* Wire, if you wish to get it for cheap, then you could break open your hair dryer and get the Nichrome Wire, or if you wish to use it for some professional works like making fiberglass plugs you could always visit your nearest home appliance store and get Nichrome.
Hope this helped you, Regards
Likith.
@@sailikith3576 The also use nichrome wire to ignite model rocket motors so you can find it at hobby shops that support that community.
@@matthewjameslee4647 Gotcha 😁
Fricken love this video!! Thanks
ruclips.net/video/LlV3lT4FK04/видео.html
You are doing it wrong. Use template on both sides and let the gravity cut your hot wire cutter thru the foam. Will get perfect clean surface and that that jaggy potato ;)
Hello i am making a plug from clay (Plasticine) as it is easier to work with for the project i am doing , i am wondering what you would recommend to seal the clay to prevent it from affecting the gel coat or resin.
Cutter is awesome..
You can buy the EC Cutter here:
www.jamestowndistributors.com/userportal/show_product.do?pid=2286
TotalBoat
Awesome, I was planning on doing the same thing for my body fenders
ruclips.net/video/LlV3lT4FK04/видео.html
@@usamafareed4786 What a dirtbag you are, just keep promoting the same stupid video for your business.
Спасибо тебе добрый человек)!
Put a small level on the handle will help.
Amazing guidelines... thanku
Definitely using this on my 62 lone star👍🚢 SUBD
Is this material used to build a mold for a fiberglass tub? Thanks.
Yooooo!!!!!! This is the best idea ever!!!!!!!
Hey fren. Did you just use copper wire for both the anode and the cathode on the battery charger? Or do you have to use a different type of wire for the cathode?
What kind of foam is that? You use the brand name (Pink Panther insulation foam) but I'm in UK and we don;t get that here. Is it polystyrene or polyurethane or what? Once I know the material, I can find some. Thanks.
Thanks for the great, informative video!! Sir doe's this not burn the battery charger up or cause any problems with it? Also what do you set the charger on? Thank You!!!...
ruclips.net/video/LlV3lT4FK04/видео.html
spray 3M adhesive lightly so as not to melt the foam
I've used the "G" string (from guitar) for best results, however, you want the lowest setting on your charger or it will quickly melt your wire ......it gets red hot and breaks apart. Or maybe a supply with multiple amp knob to adjust it perfectly .....maybe a model train power supply ? ? Anyone know ? Thanks.
Depending on amperage you could add a potentiometer to the circuit i think?
What glue do you use, I use liquid nails and it does not to form well.
Thanks
Supper 77 spray adhesive.
I know this is an old comment, but for anyone reading it now, low temperature hot glue works great.
Good
Thanks
What kind of glue did you use to glue the foams together?
ruclips.net/video/LlV3lT4FK04/видео.html
I thought when you glue foam together the spray adhesive would melt it.
What gauge of ni-chrome wire did you use? Do you answer questions?
Really helpful vid
ruclips.net/video/LlV3lT4FK04/видео.html
@@usamafareed4786 What a dirtbag you are, just keep promoting the same stupid video for your business.
this was great! thank you!
(facepalm) I've used pink (ore Lowe's green) foam and hot wire to make R/C planes for years. I was looking at my bike last weekend and thinking, " I want to make a cafe racer seat, but there's no way I'm buying sheetmetal tools just for that." GREAT IDEA.
Have you made any progress on the cafe racer seat? I'd love to see some pictures.
What kind of adhesive do you use for gluing the foam boards together?
A 3M spray adhesive!
Protip on the cutter...its easier to put the hotknife in a vise and move the part.
That Pink Panther Foam smoke is really healthy??
What aerosol glue is that? I tried the 3m headliner adhesive and it melted my foam board (i had the green version of that stuff.
I believe we had used 3m super 77
If you had two templates to sandwich the foam ..?
Can i use epoxy resin for fibreglass mat..?
hallo there something i would like to ask you if you know if its possible i am making a sculpture from clay only and the clay i use a lot of is air drying clay and i want to learn how to use fiberglass but i dont know if i can make a plug from my clay master first do you think it is possible for me to make a plug from my clay statue i will be making in the next few days ok
What did you used to glue the foam layers together and does it effect the cutting with wire ?!
3M spray adhesive Super 77
TotalBoat
My company, SouthernCarlson,
Sells among other construction & manufacturing supplies, bulk spray adhesives , many of which are sold in aerosols for smaller applications.
Let me know, if you’d like further information.
We do a considerable amount of business within the Industrial /Manufaturer sector,
Such as boat manufacturer, Modular building manufacturing, trailer & utility trailer manufacturing, cabinet & countertop manufacturing, plus many more.
Thanks
Nice!!!!
ruclips.net/video/LlV3lT4FK04/видео.html
Can u make a video on ,,how to make FRP Lip ?
Can you make a vid on how to make the cutter??
super!
What type of glue did you use to bond the foam boards together. ..thanks
super77 probably
I can smell the plastic smoke from here!
youtube put you thru 45 sec on adds to see this video.
what glue did you use?
I wanna make custom louvers for my rear side windows like the Mustangs have nut for my 1975 nova how would I go about doing this
ruclips.net/video/LlV3lT4FK04/видео.html
@@usamafareed4786 What a dirtbag you are, just keep promoting the same stupid video for your business.
How to make a plug for a full size car?
what foam you use?? XPS or EPP foam??
ruclips.net/video/LlV3lT4FK04/видео.html
@@usamafareed4786 What a dirtbag you are, just keep promoting the same stupid video for your business.
Can i use clay as an alternative to the foam for molding?
ruclips.net/video/LlV3lT4FK04/видео.html
@@usamafareed4786 What a dirtbag you are, just keep promoting the same stupid video for your business.
Where did you buy the foam from?
whats it is name for this material
Can u plz tell us where u but this foam and how much it cost?
you can buy this pink INSULATION FOAM at any hardware store or Home Depot, etc.
It was a simple way to make a plug and didn't cost a lot.
Turn power up...Not enough smoke
Inhale for long life
Hello
What material is the pink insulation? Styrofoam?
Thank you in advance
It's a pink insulation foam board meant for home use - available at Home Depot, etc.(pink panther Insualtion foam)
it's pink panther insulation foam. never been in home depot?
@@spiralarray1969 Stay away from home depot - might meet you there.
Which foam have you used in this model?
PINK PANTHER INSULATION FOAM.
@@TotalBoat thanks
Where did you get that insulation foam?
Any home depot
can you give the link of the foam you are using?
ruclips.net/video/LlV3lT4FK04/видео.html
May I know what is the name of the foam you used? Thank you!
Yeah he said it at 0:25 but I cannot spell it, its so slang. Can you please tell me? Sorry, it my first time to hear the term. For me its look like a floral foam.
Pink Panther Insulation Foam
This pink material is a styrofoam or foam ?
Insulation, you can find it in home depot or lowes
@@martys.5617 Don't use styrofoam makes gas
is that epoxy for a boat used ??
Yes! TotalBoat 5:1 Epoxy. You can buy it here: www.jamestowndistributors.com/userportal/show_product.do?pid=64343
what kind of wire do you use?
can't say for sure but i would use nichrome wire.
Where to buy this foam
He used the pink panther insulation foam. You should be able to find it at home improvement/hardware stores!
why type of foam is this??
The foam used was Owens Corning FOAMULAR 250
This guy needs to calm the hell down!
lol
Yeah... I'm going to be a critic and say that pink insulation foam is a crappy material to work with. The solvents and catalysts used in most fiberglass resin/gelcoats react with the pink foam, hot glue melts the foam, body filler does not stick to the stuff at all... Frankly it was a pretty bad suggestion. Just use clay and/or cardboard, then use body filler. It will save everyone the trouble.