How to Create a Fiberglass Part From Scratch - Beginners Guide

For this video, we are going over the steps to create a master cylinder cover for a S550 (2015-2023) Mustang from scratch. The idea behind this video is to show you how to create parts from your imagination or even a simple modification. The steps will include creating a shape (plug), the forming a mold, then making a part.

========== Plug Creation ==========
1. Intro - 0:01
2. Background Story - 0:33
3. Step 1 (Shape the Plug) - 0:47
4. Step 2 (Sand Plug Surface) - 8:52
5. Step 3 (Clean Surface - IPA) - 9:19
6. Step 4 (Apply Primer) - 9:42
7. Step 5 (Sand Primer) - 10:32
8. Step 6 (Clean Surface - IPA) - 11:02
9. Step 7 (Apply Clear Coat) - 11:14
10. Step 8 (Wetsand Clear Coat) - 12:11
11. Step 9 (Polish Clear Coat) - 12:43

========== Mold Forming ==========
12. Step 10 (Attach Flange Material) - 14:13
13. Step 11 (Clean Off Excess Glue) - 15:41
14. Step 12 (Fill In Mold Gaps) - 16:08
15. Step 13 (Apply Mold Release Paste Wax) - 18:00
16. Step 14 (Apply Mold Release Agent) - 18:46
17. Step 15 (Apply Tooling Gel Coat) - 21:19
18. Step 16 (Layup 30gsm Fiberglass) - 23:21
19. Step 17 (Layup .75oz Fiberglass) - 24:15
20. Step 18 (Layup 1.5oz Fiberglass) - 25:46
21. Step 19 (Layup 1.5oz Fiberglass w/Wax) - 28:07
22. Step 20 (Trim Mold Edges) - 29:01
23. Step 21 (Demold Plug) - 29:48
24. Step 22 (Clean Mold) - 30:46
25. Step 23 (Wetsand Mold) - 31:09
26. Step 24 (Polish Mold) - 31:45

========== Part Making ==========
27. Step 25 (Apply Mold Release Paste Wax) - 32:29
28. Step 26 (Apply Mold Release Agent) - 32:55
29. Step 27 (Apply Gel Coat) - 34:19
30. Step 28 (Layup 30gsm Fiberglass) - 35:46
31. Step 29 (Layup .75oz Fiberglass) - 36:02
32. Step 30 (Layup 1.5oz Fiberglass w/Wax) - 36:35
33. Step 31 (Demold Part) - 37:31
34. Step 32 (Clean Part) - 38:16
35. Step 33 (Trim Off The Flange) - 38:55
36. Step 34 (Sand Edges) - 39:18
37. Step 35 (Drill Holes & Notches) - 39:57
38. Step 36 (Test Fit Part) - 41:30
39. Step 37 (Paint Part) - 42:04
40. Final Product - 43:01

Products Used:
This video contains affiliate links for which I may receive compensation.
========== Mold Material ==========

========== Disposable Material ==========

========== Misc Products ==========

Tools:
Applicator Pad
Center Punch
Circular Saw
Gelcoat Gage
Glue Gun
HVLP Spray Gun
Isopropyl Alcohol 91% (IPA)
Jig Saw
Microfiber Cloth
Oscillating Tool
Popsicle Sticks
Rotary Power Tool
Safety Glasses
Sander
Sandpaper (80-2000 Grit)
Shop Towels
Stepper Bits
Trim Removal Tool Set
Utility Knife

#Fiberglass #MoldMaking

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