Excel 435 HD fit out from scratch - Page 9

jeffstevens763@g · 04 January 2021, 11:50

back with this so i got the mould rubbed down and 12 coats of polish on it. in the mean time i experimented with the PVA i would have liked a minute pimple finish which i could achieve with the preval sprayer but it flattens out during cure, does the same with a brush stipple to so i ended up with a sponge finish. i cast the floor on a piece of HDPE one coat of polish and the PVA when cured prized the edge to release really easy i washed the PVA off and ended up with a matt finish good enough for the floor since its hid inside the console.

jeffstevens763@g · 04 January 2021, 12:01

got the mould polished and the PVA applied by sponge [micro pore ], i cut all the matting with an overlap of an inch each side so its double thickness on each corner i also staggered them so it kept it just one layer high when its finished.

2 layers of 100g chopped strand matt
2 layers of 225g
1 layer of 300g

I'm finishing off with

1 layer of biaxial cloth for a bit of strength and a smoother finish.
i did find it quite difficult to work inside such a small area so i did it in layers over a few days. i also found that i had to stand it up on the top because the edges would start to fall off the mould, no big one as the mould is made to stand that way and a quick stipple around the edges to finish made all good.

jeffstevens763@g · 05 January 2021, 11:43

got the glassing finished trimmed the edges with a multi tool, cut to shape the floor ill flow coat above it first before glassing it in from underneath, i have some 50mm tape cloth to do that's a bit neater finish than chopped matt since its a cloth finish anyway. I'm going to leave it a few days for full cue before splitting from the mould.

jeffstevens763@g · 05 January 2021, 13:22

thinking forward to fit out I have three of these hatches they are kayak hatches decent quality for the money. max dia is 8 inches I'm thinking one on the top, one bow side and one on the long side which will leave me quite a sizable area below the floor to fit the battery if I want to leave more room above the floor in the main compartment for the dry bags which will have phone, car keys, hat , gloves etc and the internal wiring and the fuse box.

jeffstevens763@g · 06 January 2021, 11:22

https://youtu.be/IbE2QwBTgc8

split the mould and cast apart 80psi to release it, with bungees wrapped around to supress movement it lost its seal at an inch out of the mould, pushed it out further with increased pressure and volume to 3 inches then pulled out by hand.

Steve509926 · 06 January 2021, 11:34

And!!!!!!!

You cant just stop there Jeff, now need to see it fully out of the mould. Following your thread has been one of the highlights of Christmas and New Year

jeffstevens763@g · 06 January 2021, 11:39

https://www.youtube.com/watch?v=pY0DioXSa3o

your wish Steve here you go glad you liked it I'm going to ask mods if they can split this out and have it stand alone so it can be searched for anyone interested.

jeffstevens763@g · 06 January 2021, 11:43

its straight out of the mould not washed the PVA off or sanded down the edges , I'm delighted with it.

Steve509926 · 06 January 2021, 11:46

I'm not surprised your delighted, it's looking really good

36valley · 06 January 2021, 11:49

Looks good Jeff.

Pikey Dave · 06 January 2021, 11:51

Looking good Jeff, very rewarding [emoji106]

jeffstevens763@g · 06 January 2021, 11:59

thanks lads much appreciated I must admit my bum was going sixpence half a crown when I did the initial split that's why I didn't film it, I know how powerful compress air can be still no damage to mould or cast. in hindsight I think a foot pump would be better so you can control the pressure more. the fit out next

jeffstevens763@g · 06 January 2021, 14:11

I've washed it off and got rid of the PVA, I'm very slightly disappointed in that the shaded areas, its like I have the matt finish there which i wanted but the rest is shiny more shiny than matt should be. i could buff it all up for a shine or flat it off with emery paper for a dull finish. i will play with the floor bit to see which is best. i don't know the reason for it as i spent a lot of time with the PVA or was that the problem? if id used the smooth PVA i might have got a good shine all over.

36valley · 06 January 2021, 14:20

Quote:

Originally Posted by jeffstevens763@g

I've washed it off and got rid of the PVA, I'm very slightly disappointed in that the shaded areas, its like I have the matt finish there which i wanted but the rest is shiny more shiny than matt should be. i could buff it all up for a shine or flat it off with emery paper for a dull finish. i will play with the floor bit to see which is best. i don't know the reason for it as i spent a lot of time with the PVA or was that the problem?

Sadly that's always the risk with mat pva. We used to price jobs with mat pva knowing it was a pain to apply and that we would lose a few because the effect wouldn't be even enough.

As you say, play with the floor to see which gives you the best result.

It's still a great effort for your first go.

jeffstevens763@g · 06 January 2021, 15:23

Quote:

Originally Posted by 36valley

Sadly that's always the risk with mat pva. We used to price jobs with mat pva knowing it was a pain to apply and that we would lose a few because the effect wouldn't be even enough.

As you say, play with the floor to see which gives you the best result.

It's still a great effort for your first go.

thanks mate makes me feel better, the good thing is there's a lot to be cut out for the electronics and hatches which will take the eye off the finish as you say ill play with the floor starting with polishing out. if all fails ill flatten back and flow coat with a very fine roller which will give a slight pimple finish.

Pikey Dave · 06 January 2021, 15:28

Quote:

Originally Posted by jeffstevens763@g

thanks mate makes me feel better, the good thing is there's a lot to be cut out for the electronics and hatches which will take the eye off the finish as you say ill play with the floor starting with polishing out. if all fails ill flatten back and flow coat with a very fine roller which will give a slight pimple finish.

Personally I’d buff & polish the lot before you start doing the cut outs. Like you say, by the time all the holes are cut, you’ll never notice.

jeffstevens763@g · 06 January 2021, 15:43

Quote:

Originally Posted by Pikey Dave

Personally I’d buff & polish the lot before you start doing the cut outs. Like you say, by the time all the holes are cut, you’ll never notice.

yea your right Dave I've just rubbed a small area by hand with TCUT with some result so i think ill get some rubbing compound and get the drill out and buff it up not exactly what i wanted but as 36V says its the first one so not going to beat myself up

Pikey Dave · 06 January 2021, 16:48

Quote:

Originally Posted by jeffstevens763@g

yea your right Dave I've just rubbed a small area by hand with TCUT with some result so i think ill get some rubbing compound and get the drill out and buff it up not exactly what i wanted but as 36V says its the first one so not going to beat myself up

Try some G3 with plenty of water & a squeeze of washing up liquid.

jeffstevens763@g · 06 January 2021, 17:40

Quote:

Originally Posted by Pikey Dave

Try some G3 with plenty of water & a squeeze of washing up liquid.

Cheers Dave G3 do I get that from halfords or auto shops?

Pikey Dave · 06 January 2021, 17:44

Quote:

Originally Posted by jeffstevens763@g

Cheers Dave G3 do I get that from halfords or auto shops?

Halfords have it or any car spares/refinisher supplies. It’s a bit more aggressive than tcut. Use it to cut back the surface, then move to tcut & then polish.