Week of April 22nd

Heavy Body Repair

Patches to be made before body work.
carburator stand off small gas fill hole
Hole to be repaired Tail light Holes

Using vintage fiberglass to repair vintage fiberglass.

For this next segment I will show how I like to use vintage fiberglass to make our large repairs.  This may seem strange or cheap to the layman but to the contrary I have to cut up a dune buggy body for the materials.  The reason for this method is the vintage fiberglass is thicker and more stable than making a brand new patch which can crack and separate.
Old gas fill with new feul door Hole cut to recess feul door into the body. Old fiberglass cut to make second level on hood to allow for recess. Recess panel in place.
Instead of cutting 2 patches I made one. I traced the outline of the removed piece to make the patch. Patch snapped perfectly in place with very little kurf. Three panels in place.
Small patch for front fenders.

I used ABS plastic and dry wall screws to hold the patch panels in place.  I cut the ABS plastic oversized to fit over the damaged region, laying the patch panel face out against the smooth surface of the ABS (texture side out).  I used ABS plastic because the fiberglass resin will not stick to it and it is rigid enough to maintain shape.  I will be using dry wall screws to attach the scabs.
It is easier to back drill the screw holes because the fiberglass is more difficult to but a screw through than the ABS. Screwing the pieces together.
Sheet stock of 1/8th inch ABS. I cut the ABS to cover patches and overlap body.
Scab in place. Rear section ready to go.
Scab ready for install. Position scab like a jigsaw puzzle. It should snap into place.
Back view of the patches. Back view of front patch. Note: screws coming through.
Front section ready to go.

I trimmed all the dry wall screws flush to the inner body.  This will make fiberglass repair much easier with no obstructions and the screws will be easily removed.
I used miniature bolt cutters to trim the screws. A cut off wheel would work just fine. Trimming is done.

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Tj Kustoms @516-338-8746
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