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1978 Honda NC50 Restoration

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  • #46
    I hope you're keeping the mould and making a few more - sure there'd be some people in the market for them being that you cant buy them anywhere (except for banged up 2nd hand ones)!
    Rigby "No dude, you're doing it wrong! Righty-tidey, lefty-losey! Not lefty-tidey mess it up because you're a loser!"

    ZRX1200S, RGV250 VJ22, Skyteam T-Rex, Z50J1 '78, XV250 Virago

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    • #47
      Take 2

      A bit of a setback with the gelcoat!

      The first coat was too thin so when the second coat went on the resin bleed through and damaged the surface of the plug.

      I had to completely start from scratch as the gelcoat stuck to the plug.

      Anyway back on track now, i sprayed the PVA over the whole plug this time and that should protect the plug surface.

      Then 2 THICK layers of gelcoat have been applied and three layers of fibreglass cloth for edge strength

      Next i will be applying 3 to 4 layers of chopped mat for overall strength of the mould and mounting stiffening board.

      Fingers crossed this will be the last time i need to do this to the plug.

      Cheers.

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      • #48
        Top job mate!! Can't wait to see the finished product.
        Save the monkeys

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        • #49
          Here are photos of the back board in place and the detail of how i supported the flange with cardboard and hot glue.

          Also a shot of the tool turned over.

          Just need to wait a few days for it all to cure then i will trim the flange and remove the plug.

          Hopefully it wont be too much hassle as the old guard is quite flexible and should release easily!

          Cheers.

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          • #50
            Just need to wait a few days for it all to cure then i will trim the flange and remove the plug .




            Got to be a joke in that right there ,,,!!!
            Awsome stuff
            Keep it up .

            Ohhh ,, not long till gp season
            its engine oil madge ,,,
            Your soaking in it ,,!!

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            • #51
              Got the use of a multi tool from a friend so i trimmed the flanges and all the vibrations caused the plug to release itself from the mold!

              Awesome result. The mold is pretty perfect just a couple of pinhole bubbles on the edge but i will mix some gelcoat and fill them.

              The PVA did its job but does leave a light surface texture on the mold surface so after a light sand it should be good to go.

              Cheers.

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              • #52
                A few days.......we cant wait that long. You have to put picts up of other stuff on it.

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                • #53
                  Going back to the final drive sprocket i had cut we found that the pitch is an odd size at 8.5mm

                  The normal size pitch for that size chain is 8.00mm

                  Lots of motorcycle manufactures use special size chains and sprockets

                  Anyway the sprocket cutters did not have or get a hold of a 8.5mm Hob, so i ordered one from a company in India who specialize in sprocket and gear Hobs

                  The Hob arrived today and here are some photos of the two sprockets against the Hob.

                  I will get a few cut at once and if they work i will hopefully sell some to recover some costs.

                  Cheers.

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                  • #54
                    Here are some photos of the first layup in the rear guard mold.

                    First i waxed the mold surface a few times then a few coats of PVA mold release.

                    Next a coat of white Gelcoat was applied and once tacked off a layer of surface tissue then a layer of cloth.

                    Allow to cure to a stage where i can trim the excess without lifting any fibres

                    Then i applied a final coat of Gelcoat and allowed it to tack then applied PVA to seal the gel from the air so it will cure completely dry.

                    Cheers.

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                    • #55
                      mmmm. don't ya just looooovvvee fibreglass.

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                      • #56
                        It sure is amazing stuff Peter.

                        Here is the first guard out of the mold.

                        Turned out really good. Just need to fine tune the mold a bit around the edge.

                        Also a bit too flimsy i will add a couple more layers of mat on the next one.

                        Cheers.

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                        • #57
                          That's an amazing amount of work mate - great job.

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                          • #58
                            you have a great range of skills , top work

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                            • #59
                              Hi there,

                              I have been working on the front guard mold and finally finished!

                              Hope to start laying up some new guards soon.

                              Cheers.

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                              • #60
                                Here are some photos of the foot rest covers being prepared for silicon mold making.

                                The covers are first mounted on to a board with clay.

                                The clay is then smoothed out in line with the bottom edge of the part.

                                This will form the parting line of the silicon 2 part mold.

                                I then used a paint brush handle to put registration holes in the clay so that the silicon will flow into them and when the 2nd part is poured, with the clay removed, it will locate the two parts of the mold for pouring the mold plastic.

                                More to come!

                                Cheers.

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