Front bodywork complete. Delta Ligero prototype custom car

With the front bodywork plug nearing its final form it was time to start the process of coating it with a high gloss paint and starting the mould creation process. The purpose of this step is to make the surface as smooth and hard as possible to make sure that the fibreglass laid over the top for the mould creation doesn’t stick to it. The blue layer in the images below is a PVC releasing agent that further improves the chance of the fibreglass not sticking to the plug and destroying everything. 

Next step is the gelcoat, which is a spray-on layer that creates a smooth surface as the inside of the mould. The gelcoat is designed to stick to the fibreglass of the mould laid over the top of it.

Once the gelcoat is cured appropriately fibreglass is laid over the top.

Once the glass has cured properly the moment of truth arrives when it’s time to separate it from the underlying bodywork plug. If you’re a genius like Will from Joe Bradley Fibreglass the result looks like this, with the gelcoat that forms the inside of the mould separating from the high gloss plug perfectly at the PVC release layer:

Once you’ve got a mould the next step is to wax it thoroughly to allow the fibreglass that you’re going to lay in it for the actual panel to release. After that the mould is coated with another coat of gelcoat (grey this time) and the glass is laid up and allowed to cure.


And then all going to plan, finally you pull out a perfect body panel!

Ready to test fit on the car. 

Thanks for looking. dan.