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Old Streetfighter Motorcycle Forum Post 09-07-2018, 03:15 AM   #1
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Default Making a mould

First off am I over thinking it!! Some times I look at something and think is complicated or too easy ( generally turns out not to be).

The tank covers on the XSR are aluminium. And come away in three parts. The third is the plastic trim that covers the two metal bits at the top.

So I'm thinking I could make a mould of the two metal side panels. This would mean I could have a 2nd set painted how I want with out messing with the original one. From the mould I would in the future like to try carbon fibre too as these side panel retail for +700.

Looking on like making a mould and then fibre glassing covers looks way to simple. I'm just trying to make sure I'm not over thinking it. In my head this should be an easy mould to make as the part it there, in ridged metal and relatively simple to cast.

Besides you guys make it look far to easy.

So for my own insecurity sake is it as simple as the following ( minus the time and work involved).

Sand the inside of the covers with 1000grit
3x layers of wax release
3x layer of gel coat (2% catalyst)
4-6 layers of glass and resin ( 2% catalyst)

Sand the mould more wax and g2g for making my covers????

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Old Streetfighter Motorcycle Forum Post 09-07-2018, 04:57 AM   #2
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Default Re: Making a mould

numberboard mould i made had one layer of gelcoat and a couple of layers of glass, but I'm just winging it
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Old Streetfighter Motorcycle Forum Post 09-14-2018, 02:39 AM   #3
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Default Re: Making a mould

You'd wanna pull a mold from the OUTSIDE of the covers or you'll end up with miniature parts. Pull mold from outside of covers, finish/wax inside of mold, pull parts from inside of mold.

This way the outer surface of your part is a copy of the out surface of the original cover. If you make something and pull parts off the outside of it, that's a buck, not a mold, and then only the inner surface would be a finished part out of the mold, you'd have to build the outer surface up to the right dimensions, finish it etc.

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Old Streetfighter Motorcycle Forum Post 09-14-2018, 02:50 AM   #4
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Default Re: Making a mould

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Originally Posted by TURNIP View Post
You'd wanna pull a mold from the OUTSIDE of the covers or you'll end up with miniature parts. Pull mold from outside of covers, finish/wax inside of mold, pull parts from inside of mold.

This way the outer surface of your part is a copy of the out surface of the original cover. If you make something and pull parts off the outside of it, that's a buck, not a mold, and then only the inner surface would be a finished part out of the mold, you'd have to build the outer surface up to the right dimensions, finish it etc.
Cheers turnip.

If I go down this route, which was my original plan but my concern is not damaging the original part. So what's the best way to protect the paint, wrap it in cling film or something?

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Old Streetfighter Motorcycle Forum Post 09-14-2018, 11:05 AM   #5
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Default Re: Making a mould

Wax it really good and then use a pva mold release - it is water soluble so can be washed off with soap and water. Best to spray it on, but can be brushed too. I would brush 2 coats, let it dry well, then go ahead.

Any good marine supply will have at least a small bottle of it.

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