Large Glass Project

I am a member of the Ohio State University Challenge X / Future Truck team ( www.osuchallengex.org ) and I am going to take on the task of "molding" our 12 or 14 inch LDC Touch screen into the dash, along with the dvd player and 4wd controls. Since the screen is so large, we are going to have to preform surgery to the dash and I have a few questions as we plan the job.

1. We dont want to glass right to the screen, what would be a good way to make a "square hole" for the screen and dvd player(computer dvd) so that the glass doesnt directly adhere to them.

2. What is a good way to attach it to the dash, over the screen so it is removeable yet just slide around? (clips or some sort?)

3. Whats the best way to "make a mold" to the existing dash and hole for the LCD screen? I was thinking maybe a styrafoam block shaveed down, then lay the may over that (with foil in between so it doesnt stick).

Thats a good start, Ill post some more as I get some replies.

Thanks in advance!

For #1: I usually start with some extra platic pieces of install kits I have laying around the shop. I use the screen's shroud and make a frame, and use Duramix 40/40 adhesive. If you don't have a shroud you can measure one up with the existing screen and use 1/4" or 1/2" MDF. Then you will have to frame that up to the dash. Fiberglass won't really work that well if your dash is plastic, stick with the 3M Duramix products for best results. Fill past is 40/58 (use this instead of bondo).

Not sure what you mean about #2.

For #3: You can use the dash you have now to make the mold. I know JL's website has information on making a mold. You will have to use mold release.

For trunk panels, I usually just cover the panel with masking tape, and paint a layer with fiberglass weave (not mat), then just pull it off after it dries. It comes out really nice, and is simple.

DXAV

One of the guys has an awsome drawing he drew, ill have him scan it so what im saying makes more sence, thanks for the reply.

Sounds good, does the other stuff I mentioned help out?

DXAV

Yes, I want to get a materials list put together.

Can you recomend a place that sells it all, and had good prices?

What type of matt will I need, its not really load brearing, just for looks. Also, how much matt/resin should something like this need.

Anything other than brushes, roller, measuring cups, fill paste, matt and resin?

Is there a dremmil bit exclusivly for fiberglass, or will out diamond edge one work ok or better than a regular cutting wheele?

Thanks again

I use US Composites. The staff is super friendly, and quick to respond. Everything on the site is priced effective, too. Shipping is fast, but watch out for the haz. mat'l charges on larger orders.

I have done everything with 2 oz chopped mat lately. Pick up some weave, too, so you can get practice with it. I usually use mat for enclosures, and weave for doorpanel fabs and dash stuff.

This is a small project. If you have used glass before, and plan on using more within the next few months, buy a gallon of resin. If you have a local PepBoys, pick it up there, it is cheaper. Pay tax, unless exempt, but not shipping. Bondo brand resin has been ok for my latest projects. It only has a shelf live of about 3 months, then it won't harden anymore.

The amount of glass you need depends on how much you really want to do. If you have one larger piece of dash, and you want to glass the whole thing, you will need more than if you want to only glass in the monitor, sand, fill, then texture coat it.

US Composites sells brushes and buckets for cheap. I never used a roller, they are somewhat useless everytime I tried them. The more you buy, the more $ you save. Fiberglass never goes bad, and you never know when you may need more. I usually by 10 yards at a time. Recently, I have bought the 6" roll, which is slightly more, but it's faster to cut and apply.

For fillers, I use Q-Cells, they work great. This would be the only filler for your application. For enclosures, you can use sawdust (cheap). You can also try talc. I bought a 5 lb of it, it works OK, and is much cheaper. It also helps get the resin off your skin. I would suggest long sleeve shirt during application, though.

I use a rotozip for cutting under 1/4" thickness, it is easy to control and works better than the dremel wheels. Sanding I use a D/A sander (with air compressor). All kinda depends on the tools you have available.

Good Luck,
DXAV

as far as tools, we have just about everything and anything one would ever need since we have space at CAR, the center for automotive research.

what is the differance between weave and matt?

I still have to get some more info about the project but i really apreciate the help given so far!

Sprayed has the right answer.

The only thing I would add, is that mat is much better for structural integrity. Being thicker, and having the strands pressed [as opposed to woven], helps build strength.

The weave is great for molding applications where show is more important than strength. You can glass a whole dash board with 1 or 2 layers of weave, without much added thickness, and then bondo and paint for a quick custom look.

No sweat with the help, we are here to help. (Though I seem to write much more than a number of other members. I reall don't have this much time either!).

Get those pics up, too!

DXAV

here are some drawings that my friend drew up of the idea....

Wow, hella nice sketches!! The placement looks fairly simple. You should have no problem adding that screen in.

DXAV

dxav] wrote:

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Wow, hella nice sketches!! The placement looks fairly simple. You should have no problem adding that screen in.

DXAV

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yea, he did an awsesome job, took him about 10 minutes to do the whole dash one, then he did the others off of that.

Ok, so we just ordered a ton of styrofoam that I am going to use to make the shape that I am going for.

Would It be a good idea to make the shape on the foam, than glass over that out of the vehicle? Then I can just pop it off and cut/sand as needed? I would of course put some foil or release agent on it so it does not stick. Should I have any problem cutting it with tools such as a dremmil or rotoip? When it comes to sanding, I will plan on using the shop air with the air powered sanded, what grits to start/end with?

Thanks again for all the help guys, I reall apreciate it!

I think the foam would work pretty well as long as you can get the exact size that you want for the screen.  And yeah I would say that you could be able to just glass right onto the foam and it would work, but I would put foil on it. I would think that even with the release agent on it might still soak into the foam, and that wouldnt be good at all.  As for the dremel and the rotozip, they are great tools for small fiberglass applications I used my dremel alot on my box. As for the grits I would think it depends on how the glass looks if its fairly smooth and not a lot of bumps and stuff I would just use like a 80 to 100 grit and then go up. Thats just my opinion.

Ok....so its about time to order everything from US COMPOSITES.....

Can someone please help me make a list of what I am going to need from glass and resin, to a filler of some sorts. If possible please include the specific #'s so I dont screw up the order....

It should be enough to do the dash project with some left over for small projects here and there.

Im thinking:

Brushes
Mixing cups
Resin /Hardener
Matt
Filler of some sort?

Thanks

I actualy was able to make a list, but what to use instead of bondo? I didnt see anything on thier site.

Duraglass works well, good and strong too. Just kind of hard to sand sometimes.

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Learning the trade one fiberglass creation at a time!