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Old 09-29-2015, 10:39 AM   #309
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I'll try and get the valance removed this weekend. From there I'm going to have to figure out the best way to make the repairs. My assumption is it should be repaired and then test fitted again to make sure nothing has changed. After that we'll have to figure out how/when/where to get a mold made.

I'll let you know when I've got it removed.

Brad
Just a suggestion Brad, but what about doing a repair to allow the mold to be taken (which maybe could be done using softer/quicker materials) and then use the mold to make a new valence rather than spending a lot of time getting yours perfect?
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Old 09-29-2015, 03:26 PM   #310
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Martin,

What you're suggesting is pretty much what I was thinking about doing. I'm not sure whether I would use my original ABC plastic valance or one made fiberglass. That decision can wait until I get the valance off and inspected closer.

The rest of this week I'll be re-organizing the shop to make working on and around the Argosy easier. With luck I can start drilling out all the rivets Friday so pictures should be forth coming this weekend.

Brad
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Old 10-01-2015, 08:09 PM   #311
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The rest of this week I'll be re-organizing the shop to make working on and around the Argosy easier. With luck I can start drilling out all the rivets Friday so pictures should be forth coming this weekend.
I guess I lied. I got the valance off tonight

Now to figure out the best way to fix it so a mold can be made. I know one thing, it's going to be a big mold!

Brad
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Old 10-01-2015, 09:09 PM   #312
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Great news Brad.

Let me know what you think about molding - not sure if you are thinking of doing it yourself or having someone do it, I am guessing it will be a split mold just to let the new part release.
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Old 10-02-2015, 05:34 AM   #313
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Please forgive my ignorance but how would you go about making a mold for a body part like that? What would the mold be made of? Then once the mold is made do you use a resin and mesh to lay in the mold to make the part? This sounds so interesting. Link?

Mike
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Old 10-02-2015, 05:57 AM   #314
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Please forgive my ignorance but how would you go about making a mold for a body part like that? What would the mold be made of? Then once the mold is made do you use a resin and mesh to lay in the mold to make the part? This sounds so interesting. Link?

Mike
That makes 2 of us. Lets pull up a zip dee chair, Mike and watch it.
If I would be looking at this task, I would consider making it out of aluminum, with may be only a shorter center section with all the curves out of ABS or fiberglass.
If you want I can forward your picture to my friend MercuryCharlie, who builds hot rods from scrap. He has extensive metal bending machinery. He may be the right person.
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Old 10-02-2015, 06:17 AM   #315
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Hi Mike

The actual principle is not that complicated and will involve taking a split fiberglass casting ) or it can be done yourself.
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Old 10-02-2015, 06:58 AM   #316
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Wow, what an art. Thanks for the link and info Martin. So many craftsman out there, beautiful to see a new one at work.........ok Brad, get on it!!!

Mike
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Old 10-02-2015, 09:52 AM   #317
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Great news Brad.

Let me know what you think about molding - not sure if you are thinking of doing it yourself or having someone do it, I am guessing it will be a split mold just to let the new part release.
Yep, sure looks like it will need to be a split mold. I wouldn't plan on doing the work myself. While I think in the long run I could do it I don't think you want to wait 5 years

Fiberglass Concepts in Somerset Ky is less than an hours drive from me so they are a possibility.

A friend of mine who is now semi-retired has helped make a mold for a catamaran and also did a fair bit of work on Corvettes and Sports Racers so he's familiar with making molds and doing the work. He's moving to Kentucky next week and since he is somewhat retired will likely be looking for sideline work to supplement his retirement income. Next week I should be able to show him the work of art and see what he thinks.

I'm going to suggest we start a separate thread detailing the repair and probable mold making of the front valance. Are you OK with that idea?

Brad
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Old 10-02-2015, 11:19 PM   #318
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Sounds look a good plan on both accounts Brad.

Please let us know how you get on; I'm keeping my fingers crossed!
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Old 10-03-2015, 07:44 AM   #319
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Ok, for those of you who want pull up chairs and follow along on the valance restoration and fiberglass mold making saga you can tune in here

Martin I do have one big question. Do you have a time frame or drop dead date as to when you will need a new valance in your hands?

Brad
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Old 10-03-2015, 08:33 AM   #320
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Martin I do have one big question. Do you have a time frame or drop dead date as to when you will need a new valance in your hands?

Brad
Not at all Brad. Bella is supposed to go back into Airstream NE to have paint and body done, and in reality, what I have done with fitting the rear bumper and trying to sort the front is more because their work flow goes:

Price the work.....give a date to do the work....receive the MH to do the work....then work out how to do the work, and it is only then that they find out parts aren't available.

So you could say this is something that I think needs to be done before body and paint, rather than find later that body and paint can't be done because they don't have the parts.
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Old 10-03-2015, 10:50 AM   #321
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I can understand that thought process!

My friend closes on his house Wednesday afternoon and he and I (I promised to help) will likely spend a month or two reworking a bunch of things that really need repairs, etc. With that in mind I'll be talking with him Wednesday evening or Thursday to get a feel for what might be happening.

In the mean time I'll start repairing the smaller cracks on the valance to get a feel for how well those repairs are going to go. For me to even work on repairing the cracks I'm going to have to come up with something to hold it in he correct shape so that should help a little once work on a mold starts.
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Old 10-05-2015, 11:16 AM   #322
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Martin, while you're taking those measurements would you mind looking at the back side of your front bumper to see if there is a support frame similar to the one in the attached picture?

Attachment 249726

I noticed that your front bumper has two mounting bolts on the face of the bar when looking at the front of the bumper. Mine doesn't have those mounting points. Instead mine has the support shown in the picture and the bumper was mounted from the top in two places and two places on the bottom along with the ones at each side.

I'm thinking of reworking the front mount to use front bolts like yours has.

Thanks,

Brad
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