Xploitn
10+ Year Contributor
- 174
- 0
- Dec 19, 2011
-
Denver,
Colorado
I will be fabricating a fiber glass sun roof plug for my 96 GSX that I am building for autocross (classed in ESP). This plug will replace the entire 27.5lb sunroof assembly. The purpose of this project is to reduce the weight at the top of my car which will help the handling, roll center and the center of gravity. It will be nonfunctional, but leakproof. I am choosing fiberglass because it's not heavy and I've done some FG with subwoofer boxes in the past. Carbon fiber is too expensive for this project and would only serve as icing on the cake since the plug would be made with primarily FG anyway. The plug will be finished off with some comprehensive applications of primer, paint, clearcoat, and sealer... rattle can style! The goal is weight reduction so the lighter it turns out, the better!
After going through most of the threads on this site and many outside of it I have a pretty good idea on the design.
I will be pulling the stock glass. I will try to peel off the seal around the glass cleanly so that I can reuse it on the plug if I decide to. I will then wrap the glass in a layer of cellophane and duct tape where its necessary. This will be the template or mold for the new plug. I will then stretch a piece of fleece over the glass and test for fitment /clearance. The resin will be mixed and applied right to the fleece for the first layer, each subsequent layer will get a layer of FG weave and resin. I will let this piece cure. then peel it off and test it for fitment in my roof hole again. Hopefully it fits!
Unknown #1: I want to bolt in down for safety and then seal it with black silicone. I am still not 100% sure how I am going to bolt it down. I am open to suggestions but I might use rivets, T bolts, or clips. My two concerns are that the FG plug will not be thick enough and that the vibrations from the road will crack the FG if I start drilling holes through it. I thought about laying T nuts or washers into the FG as I'm laying the layers down. Would this increase the possibility of cracking? If I did the washers, I would probably do pin latches similar to aftermarket hoods. I would probably only need two in the front and two in the back. These would only be for safety so that the plug doesn't eject itself when going around the course!
Unknown #2: I still need to inspect the edge of the roof when I take the old sunroof out, but I think I will be mounting the bolts/rivets/clips using L-brackets so that the plug sits flush.
Now to my questions,
Does anyone have any better ideas for a more flush solution for the safety bolts/rivets/pins, please let me know.
Unknown #3: Once I get the shell of FB done by using the stock glass as a mold, can anyone think of a good solution to use as a core for thickness?
I have most of the materials on hand from a past project which is why I'm willing to jump into this DIY project with so many unknowns.
The project will be documented with pictures, measurements, and documentation on the parts and supplies used.
As always thanks for any help and input!
After going through most of the threads on this site and many outside of it I have a pretty good idea on the design.
I will be pulling the stock glass. I will try to peel off the seal around the glass cleanly so that I can reuse it on the plug if I decide to. I will then wrap the glass in a layer of cellophane and duct tape where its necessary. This will be the template or mold for the new plug. I will then stretch a piece of fleece over the glass and test for fitment /clearance. The resin will be mixed and applied right to the fleece for the first layer, each subsequent layer will get a layer of FG weave and resin. I will let this piece cure. then peel it off and test it for fitment in my roof hole again. Hopefully it fits!
Unknown #1: I want to bolt in down for safety and then seal it with black silicone. I am still not 100% sure how I am going to bolt it down. I am open to suggestions but I might use rivets, T bolts, or clips. My two concerns are that the FG plug will not be thick enough and that the vibrations from the road will crack the FG if I start drilling holes through it. I thought about laying T nuts or washers into the FG as I'm laying the layers down. Would this increase the possibility of cracking? If I did the washers, I would probably do pin latches similar to aftermarket hoods. I would probably only need two in the front and two in the back. These would only be for safety so that the plug doesn't eject itself when going around the course!
Unknown #2: I still need to inspect the edge of the roof when I take the old sunroof out, but I think I will be mounting the bolts/rivets/clips using L-brackets so that the plug sits flush.
Now to my questions,
Does anyone have any better ideas for a more flush solution for the safety bolts/rivets/pins, please let me know.
Unknown #3: Once I get the shell of FB done by using the stock glass as a mold, can anyone think of a good solution to use as a core for thickness?
I have most of the materials on hand from a past project which is why I'm willing to jump into this DIY project with so many unknowns.
The project will be documented with pictures, measurements, and documentation on the parts and supplies used.
As always thanks for any help and input!