GS500 Brat (Cafe now...)

[moto]

I used a Plugin called Slicer, it did a pretty good job!.

https://sketchucation.com/pluginstore?pln=TIG_Slicer

[Ne0n]

Awesome, love how you spend so much work for the details and even rework the "done" thing.

[moto]

Thanks Ne0n its the details that make it, and that seat would have driven me insane 😂

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[moto]

Today I got the seat buck painted in gloss black, this allows you to see all the imperfections but also seals the surface, so I'll give this a wetsand once it's dry, polish it up and then we can start laying up some fibreglass   

[ajensen]

Looking good!

[J_Walker]

For the front of the seat, create a little fiberglass tongue between the seat and the tank, just to close up the gap. I learned this when I did my seat.

otherwise, water gets in between the tank and seat.

[moto]

More goodies arrived yesterday, fully refurbished rear caliper and new pads, one of the last missing pieces! Just need to get my gauges sorted out, seat finished and upholstered and we're almost there!

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[moto]

Slow progress on the mould, but I got the buck out of the shed and the paint went on really well, I'm not going to bother wet sanding it, it doesn't need to be perfect as I'm not laying up carbon fibre and there will definitely be some final finishing, high build primer and paint going on the final parts! No point wasting time!

I've started by giving the buck 3 coats of simple bees wax to provide a protective layer, you can buy expensive mould release wax but I've found this to be just as effective for DIY jobs. This will be followed up with more wax and a number of coats of hairspray to give a good mould release.



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[moto]

The next stage is to create a central dividing spine, this mould is going to have to be a two piece mould due to the complexity of the side recesses, this means the mould needs to be laid up in two parts. The spine is a piece of card cut to the profile of the buck then glued to it with hot glue. Once the first side is laid up you can then tear out the spine, remove the hot glue and rewax the whole lot before laying up the other side to complete the mould.

Any gaps and bumps can be filled in with a wax based clay, I have also used this to smooth any very minor imperfections. The wax can be softened up with heat and thinned by mixing and folding some of the creamy wax into it.

[moto]

Gel coat on

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[moto]

Side 1 laid up with fibre glass

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[The fink]

Awesome thread! Quality craftsmanship. I look forward to seeing more progress. 

[cbrfxr67]

[Ne0n]

me too haha

[moto]

So I made a boo boo with this one, I couldn't get the mould release due to the recess in the front and the back 🤦

Out comes the Dremel again, and off comes the front of the mould! 2 steps forward 1 step back.

So now we're making a 3 piece mould! Woop woop

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[moto]

New divider added, I will get this finish at some point !

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[moto]

Last of the mould gelcoat.

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[moto]

Annnddd the mould is finished. Almost there!

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[ajensen]

You are one of the most patient and diligent people I have seen. Good work! Thanks for keeping us posted.

[moto]

Thanks ajensen, it's taking a while, but I would rather get it right!!

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