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tips on how to do this please....

B

boardsportsrule

[H]ard|Gawd
Joined
Nov 27, 2003
Messages
1,107
ok, im gonna be moddin a case semi soon... since i've seen all these front ducts that look cool, i kinda want one, but not the norm...im thinking of riasing it out maybe an inch or two, and then bondoing it around so it gives it a curved look..almost like a pyramid with a 120mm hole on the top, but a round pyramid...a cone!!! :) so i got to planning of this, and i dont quite know.... i can sand teh bondo off, but will it have wierd divots in random places or what...any one try anything similiar and have any tips? please let me know! :)
 
bondo + dreme to get the shape down + hand sand to get the final shape + paint = u will never know
 
You can get bondo pretty damn smooth. If there are any little holes or indentations then just put a bit more bondo in and sand down.

Keep in mind that bondo is pretty heavy. If you are going to be using it mainly for moulding and forming then you might want to look in to fiberglass or something.
 
hmm, i live in a small town( sub 10k people), is fiberglass easy to come by? if so how does it work, never used it.... i have used bondo(actually used auto body filler) so i am fimiliar with how it will work...im just not sure if A) it will stay in place while it dries....i might have to make some supports, and B) if i can keep a constant curve all teh way around the duct... more info on the fiberglass would be awesome if possible... :)

EDIT: oh yea, i have no dremel, and i would prefer to keep it that way as they aren't exactly cheap :)
 
i got my dremel for 25 at home depot.

if your cutting fan holes just use a drill and a bit.

also if you want a really good chicks (hot ofcourse) ass sand then wet sand
 
yea, i got blow holes down fine using my jig saw, im just not sure about cutting down the bondo to make it smoothe...i guess i just gotta try it and if it works coool, if not to bad :)
 
Find a plastic funnel a little wider than your duct's diameter, then cut it (using a dremel, strong scissors, whatever) to the proper shape and bondo it in. That way you save on the bondo (ie. makes things lighter) and you get a more uniform shape (makes life easy). ;)
 
Not to sound wierd, but you could actually just get a block of styrafoam, cut a hole in the middle for a fan, get it in the general shape you want it, epoxy it to your case and cover the whole thing with bondo (less weight, easier than using bondo to make the whole thing)
 
Both those ideas sound really dork but I'm sure the end result would be the same, and that's what matters.

If you do buy a dremel, I'm sure you won't regret it =)
 
i actualy just did that exact same thing, just get a peice of pcv pipe the size you want the hole to be then cut a hole in the bezzle so the pipe can fit inside it. adjust the pipe how far you want it to stick out and then the easiest thing to use is bondo to get it to blend in seamless. it just takes a lot of sanding and time. im almost done painting ill post a pick in a day or 2.
 
i like the big dry vent hole cutters. i have one that is like 125mm on that cuts perfect holes in metal plastic anything
 
Ok, for the basic fiberglassing, you can get a start up kit at your local auto body repair shop that will have some mat, resin, instructions, and hardener. Depending on how tight/big the cone is, you may want to buy some fiberglass cloth to use instead (mat is much stiffer, but harder to form); this should also be at the auto body shop. When setting up the fiberglass, make sure you always are in well ventilated place (resin) and use rubber gloves (disposable will do fine). Use the funnel as a kind of mold, and if possible liberally wax the funnel to ensure the fiber glass will release. Mix the resin and hardener in the amount indicated in the instructions; the more hardener, the faster the resin will dry (note you'll be using a signifigantly small amount or hardener compared to amount of resin). Cut out a piece of mat/cloth that will be slightly bigger than you'll need (always better to err on the side of extra after all; you can always cut off what you don't need, it's trickier to add on what you did need) and use a brush to kind of dab and spread the resin on both sides until it appears soaked throughout. Put it on the funnel and make sure it is secure before allowing it to dry.

After that you can sand it or cut it to the size/shape you need, but always make sure you've got goggles, gloves, and a dust mask; your lungs and eyes don't like glass dust. :)

And yea, if you're gonna be doing alot of modding or just work on hobbies, a dremel tool is a must; I don't know how I lived without mine :D
 
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