Date:         Sun, 6 Feb 2005 10:00:23 -0500
Reply-To:     Joe Federici <joefederici@EARTHLINK.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Joe Federici <joefederici@EARTHLINK.NET>
Subject:      Re: ADVENTUREWAGEN molds - further update
In-Reply-To:  <000701c50bcb$3dce3d00$e10cfea9@9100d>
Content-Type: text/plain; charset=US-ASCII; delsp=yes; format=flowed

The aw top that's on my van was made from a combination of both hand
layup and chop mat. I've work in fiberglass kayak building and some
boat building. In Sea Kayaks this can be a common method for
production. Chop mat does have it's advantages over hand lay but if you
were going to take your time I would agree with Gary and lay the whole
thing up with cloth.

JFF


On Feb 5, 2005, at 4:39 PM, Gary Lee, Vanagon Racks wrote:

I don't want to be in the fiberglass business, so I have no interest in
> keeping the molds for myself. I would like to see them go to someone
> who can (and will) fix them up and put them back into service.
>

I was involved in the fiberglass boat business a number of years back.
It's
the same thing as what is involved in making AW tops.
I just have a couple of comments, for what its worth.
The molds have to be in good condition before they can be used.  Any
defects, marks, chips, scrapes or damage should be repaired.  The
picture of
the mold upside down in the gravel is disturbing.
http://www.weirdstuffwemake.com/weird/stuff/automotive/vanagon/
save_the_AW_molds.html
Incidentally, the intial cost to build molds is considerable.  You
wouldn't
do it if you were only planning on making 10 or 20 tops.  Having these
molds
available for free is something of a coup.

Someone mentioned using a chopper gun.  While this is faster, the
downside
is that it is also heavier and not as strong.  The difference in weight
can
be significant. Shower stalls and truck tops are often made with chopper
guns.  Small sailboats and race car fenders are laid up by hand.  Hand
lay
up is more labor intensive than chopper gun.  If it were me, I'd be
like to
have as little weight up high as possible.
I don't think vacuum bagging is specified for something like a AW top,
although it would be good.

If someone were determined, they could make a top in their driveway at
home
using hand lay up.  It does not require special equipment or advanced
skills.  It would be a two or three person job.  You should be able to
learn
the basics from books and online.
The resin and cloth are the most expensive part nowadays, maybe a few
hundred dollars worth.  The rest is labor - it's dirty smelly work.
A proper fiberglass shop has the cost of eviromental considerations and
regulations.  A guy doing it at home wouldn't have these costs.

Gary Lee
Calgary, Canada
http://www.telusplanet.net/public/gary2a/vw.htm