Anyone local to me any good with fiberglass?, I have an idea... Options

[VaccaRabite]

I like my big black bumpers, but I don't like how heavy they are.

I was thinking that I could make a fiberglass mold out of the steel insert, and then fill that with some high density foam, like modern bumpers. Put it back in the rubber insert, and call it a day.

Problem is, I don't know the first thing about laying up fiberglass.

Help?

Zach

[highways]

Having worked as a composite technician in aerospace as well as doing boat repair and composite model sailplane building... I just have to say that
:fiberglass : + :can of worms: + (IMG:style_emoticons/default/stromberg.gif) + :tar and feathered: + (IMG:style_emoticons/default/stfu.gif) = :project failure accompanied by record levels of self loathing:


Actually- there are easy ways and hard ways to do things. And there are lots of decent ideas being thrown out here. Just need some pictures, a plan, and some material test experiments to know what you're getting into.


I personally would probably start going about it as okieflyr suggested below. Carve a blank (I like hot wires), sort of 'cut and paste' to shape, add filler to shape even better, then glue into bumper. I would only worry about the density of the foam as far as 'ease of shaping' goes. But when it comes to finished rigidity you can always wrap it in some 4 ounce clothe. Real bumper foam is EPP or Polystyrene- and is very soft. This could be a 4 hour project as opposed to a 3 week mold making project.

Another, maybe simpler approach would be to make a high density foam log, and carve it to fit it the same space as the steel beam. The higher the density, the more weight. The foam can be worked like a light wood with saws,sanders, and sureforms..