molding epoxy?? making a simple mold??

[LowBuckX]

I want to make some simple base wedges to fit my new mirrors to my novas door. Where the mirrors mount there is a u shape in the sheet metal.. Id like to find something that I can mix together and lay out into the channel and let harden so I can shape it to fit.. Not like bondo this will not be a part of the door but part of the mirror base.. Does that make sence at all..... I need to go to bed.....LOL

[jackfrost]

a picture would help. but if you wax the door really well, then you can lay down some duraglass or fiberglass, depending on how big it is. once it hardens it will pop right off the waxed surface.

[vp23271]

By "base wedges" do you mean the pedestal part that attach's the mirror portion to the body of the car? Is it like the mirrors below or different?

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[astroracer]

Pick up some "All Metal" at your local body supply or use some JB Weld. Slick the door with some WD-40 and lay down a piece of wax paper. Plop the mix where you want it and get as much shaping done as you can before it kicks. If you have a base you want to use, set it in place on top of the pile to establish the height and you should be good...
Mark

[LowBuckX]

differant. I cant grind on mine I have to fab something to fit the contour

[lbdz28]

I used the epoxy puddy that POR. It comes in two sticks that you mix up. It is the consistancy of clay that sets up in about an hour. Can be sanded and painted.

[MrQuick]

I just welded on stand offs so the mirriors will mount right up. But it is VERY permanent.

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[LowBuckX]

Yea thats a little too far for me lol.. But now some one can see what Im taking about thanks..... I quess I can try a few things since its not attached to the car.

[badbu68]

I would go to the hobby store and pick up some modeling clay first. It does not dry out like regular clay, but it will harden if it's not kneeded and sits for a few days. I would use this first to figure out what kind of shape you want, maybe able to make a cast from it.

[Alchemist]

Sounds like you want to make a "pedestal" that will fit in the valley of the door and then mount your mirror on top of that.

I've done something similar, having to mount mirrors from a different vehicle to a both doors of a customer's car.

Instead of welding in a plate and avoiding having to fabricate a piece to fit the valley I went to a local surplus store and looked at all the different types of materials with which to work with. I ended up picking up a block of delrin plastic. I almost chose some aluminum blocks they had which would have been cool but I wanted to keep costs down! You can use a variety of materials but select one that will not crack or split when screwed down tightly.

Anyway, I cut the delrin just a bit thicker than requried. I made a template of the valley by bending a thin piece of metal and used this as a guide as I used a die grinder with an abrasive disc to shape the delrin. You can also use a hand block with some course sandpaper like #36-40 grit to shape the piece - even a belt sander. You can use whatever you have to rough shape the part and you don't really need to make a template. I did because I wanted a perfect fit!

When I finally had the delrin shaped to fit exactly as I wanted - I sanded the top surface - where the mirror was to be mounted - so it would sit at the desired height.

I then resanded the delrin with #180 grit, primed it with primer surfacer of your choice - blocksanded and painted it to match the car.

Another alternative is to use a two-part (catalyzed) epoxy putty. Here's one type of kit by Devcon:
http://www2.blackwoods.com.au/infoBANKProduct.aspx?SG=2000165&S=28&G=2004434&P=2027536

Apply masking tape to the door area where you want to make the pedestal. Mix the two parts of epoxy putty thoroughly! You can then apply the epoxy putty to that area, pressing into and shaping it to your desire. It's just like the clay you used when you were in elementary school to make stuff.

Let it sit for the appropriate length of time the instructions say to allow it to harden. You can final shape it with sandpaper and prep it for paint.

I used this method for a vareity of fabrication.

Hope this helps!

Alchemist