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TmVlZCBTcGVlZAo=
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993 Posts
Discussion Starter #1
I've gotten the basic form done. A lot of finish shaping and gap filling to do but I think it's a good start to a solid first-piece casting form.

I have resin and glass in hand and hope to have something usable before year-end. The end goal is to produce a bolt-on louver cover that has water deflectors(front, back, top) and ventilation.

A template for bolt holes and rough cut-out will come if I can actually produce a reproducible kit. :rofl:

The current rough form is way too high in profile at the wide end of the insert.






 

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"Bentley" Owner
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n00b
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536 Posts
Yes please.. I want!
 

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TmVlZCBTcGVlZAo=
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993 Posts
Discussion Starter #6
I'm still fighting with profile. Last night I knocked the center-side section down and created a rough scallop following the center hood separation curve. It's still rubbing the car at the top though and not seating all the way into the hood. Fun part is, I get to do a casting, in reverse, for the other side. Joy joy... Update pics soon.

The current plan for attachment is molding #8 stainless screws into polyester resin and incorporating them into structural stand-offs. The final product will be a heavy duty casting polyurethane that I can add color pigment to. Drill/cut holes, set, and apply locking nuts.

I still have no idea about hood liner trim yet. I'd like to make a liner bezel set where the top(cap) and bottom bolt together so there's additional retention force for the vent cap. I have a new liner in the garage in case I ruin the one on there. Shipping was not cheap, so I'm not going to go wild with the razor and scissors. :D
 

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TmVlZCBTcGVlZAo=
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993 Posts
Discussion Starter #7
Not much progress with other weekend projects going on.
If there really is interest in buying a finished product I'll try to focus on this instead of other mods.

Here's a pic of the "hump" I cut down and the roughly scalloped edge.
Picked up more air dry clay today and 20lbs of real clay for creating the silicone rubber molds.
Gonna try to get this one roughly shaped this weekend.

The beige color stuff is the air dry clay. I smooth it/shave it by hand with a knife and then skim the surface with drywall spackle to give a harder and more consistent layer to sand and refine.

 

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"Bentley" Owner
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257 Posts
There's a serious interest for me. At the front corners of my stock "vents" the black coloring is already peeling off to reveal white plastic beneath. While not a big enough problem to bitch to the dealer it's big enough for my OCD to kick in and want functional replacements.


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"Bentley" Owner
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257 Posts
This will be a cap and bezel kit for modification. I can get new inserts and sell a full replacement kit tho.

This is what I'm most interested in. Very frustrated the plastic is already deteriorating.


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TmVlZCBTcGVlZAo=
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993 Posts
Discussion Starter #11
This is what I'm most interested in. Very frustrated the plastic is already deteriorating.


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If you just want a replacement set I can get them from Korea or you can order them from FourGreen. They're about $22 each. I can also cast replacements in colored urethane plastic or any of the casting products from Smooth-On.

864201M700 RH "grille"
864102M700 LH "grille"
 

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TmVlZCBTcGVlZAo=
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993 Posts
Discussion Starter #12
Some on-hood shaping time today.
The scallop is gone and I've gone with a new concave line on the front to give more space for heat to escape with the water diverter.

This is a rework to some extent. It is easier to shape it on the hood than by pics and guide marks.

After staring at this for a while today I got the goofy idea of making a LH side version with an aerodynamic pod for a single gauge install. :gc-Popcorn_Smiley_b
Bad idea? Good idea?
It will take a bit more development and casting time to make something like that though. I won't consider it until this set is functional and I can mod the existing casting with an aftermarket pod.
It will fit, visibility-wise, right on the left side of the vent hump and extend the piece up about 1.5" from the hood surface.
It will be right in the middle of the steering wheel there.








The flat area facing the windshield will be a louver to prevent water from running down into the vent.

 

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TmVlZCBTcGVlZAo=
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993 Posts
Discussion Starter #14
Changed gears and am using waxboard, tape and poly resin to build up sections of the prototype.
Inside will be a forward-facing louver to reflect water towards a drain hole/slot located at the bottom corner on top.
On top of that will be an opposite angled and curved louver that covers the inner louver and shields front/top while allowing air to escape.
The top concave shape has been set and trimmed.
I have to test cast a factory grill insert to make sure the bolt studs will be retained properly and the retention clips won't break off easily.
 

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TmVlZCBTcGVlZAo=
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993 Posts
Discussion Starter #16
Rough first pieces to give me an idea of clearances and areas for reinforcement as well as attachment locations.
I think the lower diverter panel is too wide. It is a mirror of the "mesh" area.
Need more area for airflow and the angle needs to be steeper to hold and redirect more water.
Also, the cover does not have enough inside clearance so the arch has to be higher. I am trying to avoid sharp lines, though.

Here is the diverter panel




Here is the diverter panel with the cover panel


Trailing side (windshield)

Leading side (front of car)
 

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TmVlZCBTcGVlZAo=
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993 Posts
Discussion Starter #17
The diverter has been set in with resin.
I'm in the process of making this a finished casting piece.
Next, more resin fill, sanding and shaping.
Then, a test mold will be made and hopefully a colored cast will be ready for pics and installation test soon.
I'm thinking a simple angled wind and rain shield is all I should try to make for this first piece.
The base and "cap" will be cast separately and therefore can be different colors.


 

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TmVlZCBTcGVlZAo=
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993 Posts
Discussion Starter #18
Another coating of resin, some shape sanding and a coat of clear primer.
Gotta pick up some bondo and some grey primer tomorrow.

Here's vid of what stage the first core is at now.
The still pics don't capture the curves due to the clear depth of the resin.

2013 Gen Coupe custom hood vents - LH Core Part 1 - YouTube
 

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TmVlZCBTcGVlZAo=
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993 Posts
Discussion Starter #19
Finish work now on the core. Looking like a proper vent now.
Added a chunk of cardboard in the middle and set it with resin. Just put some clay around it to form an internal support and cavity separator. Once it dries, it will get smoothed and brushed with resin.
Here are some angle shots and a few with primer on.









 

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TmVlZCBTcGVlZAo=
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993 Posts
Discussion Starter #20
I couldn't help but do a trial fit today.
There are sections that are black without primer so it may look like some areas aren't flush around the edge. The whole thing fits snugly and flush at the edges.
She has a nose now! Though, it will soon get covered with a wind and rain deflector.




 
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