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Old 03-10-2016, 03:35 PM   #99
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I'm wondering if someone like Andy at Inland RV would be interested in listing the parts? He has several FRP parts listed, where the original was ABS so I guess someone has gone through the modeling process.
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Old 03-10-2016, 03:50 PM   #100
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I've been thinking about that. There are several options that come to mind. We can talk about them at the get together or sooner if you'd like.
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Old 03-12-2016, 08:34 AM   #101
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Got a text from the fiberglass shop a little while ago with 8 pictures.

Here's the text from the message he sent me "Sorry for the wait, but after 10+ hours yesterday and 2 this morning it's finally out. I was so afraid that I was going to have to call you and tell you that I would have to cut your piece out to get mold to release but it finally popped out. There was minimal damage to your original part. Pictures to follow."

Here's the pictures of the new mold:
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And here's some shots of the damage that was done to my original valance.
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After I received the text I called and talked to him about what happens next. One of the reasons it took so long to get the mold to pop free is the ABS plastic from the original valance didn't want to release and was flexing a great deal. For some reason in the process of making the mold the plastic got real soft and wanted to adhere to the mold. That's the main reason it took so long for him to get the mold to pop free.

The mold didn't come away unscathed. Apparently he has to do a little bit of minor repair to the mold before he can make a piece but he said it was no big deal and he wasn't worried about that part at all.

The bottom line is we now have a mold and he indicated by Tuesday or Wednesday of next week he should be laying the fiberglass for the first piece

Hopefully this will make Martin's day!
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Old 03-12-2016, 09:33 AM   #102
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Wow, I am really sorry the original got damaged Brad, but hopefully a new fiberglass one will be a good enough replacement.

You have said it before but I think we have really struck lucky with the vendor - they do excellent work!
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Old 03-12-2016, 11:01 AM   #103
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Doesn't worry me in the least about the damage to the original. It's damaged far far less than before I took it to him. I also think this whole episode has pointed out the fact that the original ABS valance has reached the end of it's days. Fortunately it was intact long enough to get a mold made. No matter what I could have done to make it look "pretty" again it still would have been an exercise in futility.

I think the original will be placed in the barn loft to rest for a while
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Old 03-16-2016, 03:14 PM   #104
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Just talked to Tim at Fiberglass Solutions again this afternoon and he informed me he's finished repairing the minor damage the mold suffered as a result of pulling the plug. He will be cutting it into two pieces tomorrow morning and then reassembling it as a 2-piece mold right after that and then waxing and prepping for the first production valance.

By suppertime time tomorrow (Thursday) he expects to be laying the fiberglass for the first valance. Assuming his schedule holds true he would probably break the mold apart later Friday or Saturday morning. I don't know what if anything he has to do to the production valance once it's removed from the mold. I can't imagine there would be much needed by that point.

I also can't think of any reason why he won't have a finished part ready to go by sometime Monday. He didn't tell me that but based on his progress that seems like a reasonable assumption.

Getting close...
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Old 03-16-2016, 03:40 PM   #105
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Are you going to be there for the 'hatching' Brad?

If I knew it was going to happen over the weekend I would drive down myself!
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Old 03-16-2016, 03:54 PM   #106
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Are you going to be there for the 'hatching' Brad?

If I knew it was going to happen over the weekend I would drive down myself!
I've thought about it but unless or until I had a firm time I don't think I'll make the trip. I'll definitely talk to him about though

I asked for and am expecting pictures sometime tomorrow or early Friday of the mold while it's still in two pieces. He mentioned on the phone earlier that he had to buy some longer saw blades. I'm not sure what kind of saw he uses to cut molds but I'm guessing it's some sort of reciprocating saw.

I can't imagine how long it takes to lay the amount of fiberglass matting it would take for the valance but I would think it's several hours or more which means he will be working into the evening hours on Thursday!
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Old 03-16-2016, 04:31 PM   #107
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Just as I got home from work he sent me these pictures.
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He mentioned that he wouldn't have a picture of the mold sitting in two pieces until after the first part is produced. Apparently he glues the blocks and clamps to the mold and then cuts a section at a time while undoing one clamp.

I had thought he cut the valance into two pieces and then reassembled. His way makes lots more sense!

From the looks of it he is done with cutting so first thing in the morning he'll start waxing and filling the seam with modeling clay. After that he sprays mold release on it and then it sits until suppertime.

Looking good!
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Old 03-18-2016, 04:49 PM   #108
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Martin, you now have a front valance it's done and ready to be picked up

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The tape in the center is just masking tape that he hadn't pulled off yet. I'm not sure when he plans on making the second one but I would imagine sometime in the next couple of days.

I hope it meets your expectations!


Brad
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Old 03-18-2016, 06:20 PM   #109
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That looks amazing!

If the news had come in a few hours earlier I would be part way to KY by now - seriously impressed.

I will give you a call over the weekend and see what we can sort out about picking it up, but most importantly paying the guy.

What a great start to the weekend!
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Old 03-18-2016, 06:56 PM   #110
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Seems the weekend just got better

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Old 03-18-2016, 07:11 PM   #111
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Seems the weekend just got better

So it was you!
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Old 03-18-2016, 07:14 PM   #112
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That looks amazing!

If the news had come in a few hours earlier I would be part way to KY by now - seriously impressed.

I will give you a call over the weekend and see what we can sort out about picking it up, but most importantly paying the guy.

What a great start to the weekend!
I'm sure Tim is probably looking forward to a paycheck! He might have taken a little longer than he said it would but I think the quality was probably worth the wait.
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