DIY fibeglass door pods

[martinw]

hey Guys

I recently build my own door pods out of fiberglass, an was then asked to do a DIY..

so, here it is...

Theres many ways to do this, i chose to do it like this..

start by cutting some wooden speaker rings

take som thin Wood an cut out a form that almost has the desired shape of your door pod



Now you build another just like it...   thats the tricky part



now i wrap my door Card in masking tape and start laying out the fiberglass.

give it at least to layers of masking tape to make sure that the polyester resin doesn't penetrate and damage your door Card.

dont use more polyester resin then you need to soak the fiberglass..   the fiberglass gives it strenght,  not the polyester resin.

once the fiberglass is fully hardened you can gently prise it of the door Card and remove the masking tape.

then you have af back plate that fits the shape of your door Card.

then trim the edges and you are ready to move on.



then i glue the wooden plate an the fiberglass plate together and reinforce with fiberglass and glue on a couple of wooden Blocks.

thoose Blocks are so that the screws have something to bite in...




then i pul over some stretch fleece to give it some shape....

soak it with polyester resin and let it harden...



trim all the edges Again and check the fitment in the car

then you reinforce with 2-3 layers of fiberglass

once hardened, trim edges Again and start grinding.

this takes alot of time..

eventually it will look kinda like this



this is about that time where you have to decide if want to paint it or cover it with fabric..

i chose fabric,   vinyl.

if you want to paint it you will need alot more sanding and some filler and so on... until it is completely smooth and ready for paint...

so i cover it with vinyl and this is the result :-)

have fun... :-)

any questions..  just ask :-)

[Rinconrolla]

Amazing !!!