Moldless Composite Construction 3 of 6





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Published on Jul 23, 2009

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Part 3 of 6

How-To techniques for using fiberglass without a mold. Watch the complete process of building an entire rear trunk assembly for a 1923 T-Bucket Hot Rod!

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Here is a step-by-step process:

Step One:
The first step in moldless construction is the design
Materials used:
Tape Measures
Sketch Pads
Step Two:
The Second Step in moldless constructing
is building the internal form
Materials used:
Cardboard for making templates
2' x 4' x 8' boards (2)
4' x 8' x 1/2" sheet of plywood
Drywall Screws
Wood Glue
1 sheet of 2" Polyurethane Foam (441-C)
Tooth Picks
Tools Needed:
Flexible Drafting Tool
Permanent Markers
Circular Saw
Jig Saw
Drill with Phillips Head Bit
Rasp Flies
Sanding Blocks
Straight Edge
Long Blade Razor Knife
Step Three:
The Third Step of moldless construction is
shaping the form
Materials used:
Long Sanding Block made from 1 x 4 x 8
finished Pine Board
40 Grit Sandpaper
2" Radius Sanding Block
Wood Glue
Tools Needed:
851-A Dust Masks or 350-A Respirator
Long Steel Straight Edge
Step Four:
The Fourth Step in moldless construction
is reinforcing internal mold.
Materials Used:
271 10 Yards of 10 Oz. Fabric
259-B 5 Yards of 6 Oz. Fabric
77-A Gallon of Polyester Molding Resin
69-A MEKP Hardener
#9 Acetone(For Clean-up)
Tools needed:
10-B Latex Gloves
350-A Respirator
32-B Brushes
885-A Mixing Cups
58-A MEKP Dispenser
Scissors for Cutting Fabric
Carpenter's Knife for Trimming "Green"
Step Five:
The Fifth Step of moldless construction is
to perform modifications and bondling of
Materials used:
10-B Latex Gloves
350-A Respirator
262-F 1 Yard of 4 Oz. Cloth
38-A 1/32 Milled Glass Fibers
22-A Glass Microspheres
77-A Polyester Molding Resin
69-A MEKP Hardener
Drywall Screws
Tools Needed:
885-A Mixing Cups
58-A Mixing Sticks
62-A Squeegees
129-A Grooved Saturation Roller
Step Six:
The Sixth Step of moldless construction is cosmetic finishing.
Materials used:
Body Filler
1041-A Duratec Surfacing Primer
69-A MEKP Hardener
#9 Acetone (For Clean-up)
Tools Needed:
Dual-Action (DA) Sander
Siphon or HVLP Spray Gun
62-A Squeegees
Medium Length Sanding Blocks for Final


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