E3 fiberglass Air Damn

[vanbavaria]

I’ve had this air damn mold sitting in my garage for way to long. I was lucky enough to come across this mold from one of the founding memebers of the BC BMW Club years ago. This is going to be my first attempt at replicating this air damn for my 1972 E3.

Step 1) release wax application. I’ll be doing at least three layers of partall #2 wax. They call for 2 hours cure time between layers of wax.

 

[vanbavaria]

Just finished the first of either two or three coats of the white unwaxed gel coat. Again call for a cure time of 6-8 hours between coats.

 

[Oldbmwcoupes]

If you need any help or have questions, please feel free to reach out to me. Im a sculptor and build molds for a living

 

[vanbavaria]

If you need any help or have questions, please feel free to reach out to me. Im a sculptor and build molds for a living

Appreciate that. What do you recommend the best way to trim the excess fiberglass and cleaning the edges once the plug is removed from the mold?

 

[Stevehose]

I thought an air damn is what happens when you hit a curb?

 

[vanbavaria]

I thought an air damn is what happens when you hit a curb?

Your thinking a curb plow.

 

[Oldbmwcoupes]

I use a small air grinder with a metal cutting blade. Electric grinder is just as good

 

[vanbavaria]

Ready to cut the fiberglass to size. I’ll be putting in three layers. First and third layer will be chopped strand. The middle layer will be woven roving to help keep the plug rigid.

 

[vanbavaria]

First layer of the chopped strand applied.

 

[vanbavaria]

Final two layers done. Should be able to pull the plug out tomorrow morning.

 

[vanbavaria]

Plug is pulled. Time to trim the excess fiberglass.

 

[vanbavaria]

Rough trim complete.

 

[vanbavaria]

Rough look, I think it’s gonna work out.

 

[vanbavaria]

Drilled and anchored. Just painting now.

 

[Markos]

Impressive!

 

[vanbavaria]

Primer and first layer of paint down. One more layer and a clear coat and I should be good for perminant install tomorrow

 

[vanbavaria]

Job done! Very happy . Not perfect, but perfect for a DIYer.

 

[dp]

Job done! Very happy . Not perfect, but perfect for a DIYer.

Hubba!!