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Holston's Jet Hanger

Making the Molds for the VETTE

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Making the Molds for the VETTE
Making the Vette Body Mold
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Here I am starting to build the Molds for the Vette. I am beginning with the Hood.
First, I will make the 1965 hood, because it is the smooth one.
Second, I will modify that to the 1964 configuration with "Indents"
Third, The 64 will have the "aluminium 63 trim panels" added.
 

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Here is the hood mounted in the parting fixture ready to make the mold.

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A closer look at the first surface coat

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Second surface coat applied

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two layers of 6 oz cloth and two layers of 9 oz cloth with the wood frame added last

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Here I have the hood mold "Sheet Waxed" to simulate the thickness of the hood.

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I am applying the first "Surface" coat of Epoxy to the under side of the hood mold.

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The second coat of Epoxy Aluminium filled "Surface" coat.

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Just finished applying 3 layers of 6 oz. cloth and 3 layers of 9 oz . cloth for stiffness.

Next I will drill two 1/4" holes for the indexing pins. Then remove the wax. and we are ready to make a hood skin that is smooth  on both sides!

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First hood clamped in the mold

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First unprimed Hood on the Vette!

From here  I will be making another hood to be modified into the "64 Corvette" hood with the "Indents" on both sides of the center ridge.

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Making "White" hood to modify into 63-64 hood.

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"White" male mold out of the 65 mold ready to be modified into the 64 hood.

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64 Hood Indents cut and the edges filled, Ready to make the outer skin mold.

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64 outer skin mold right of f of the "White"

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64 "Indents" have been sanded in this view. You can see the aluminium in the surface coat here,

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64 "Hood" area of the mold has been Sheet waxed with .0031 thick wax.

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.0015 Sheet wax has been added over the Hood and out to the "Pinch off". then.0031 is added to edge.

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Surface coat on the 2nd half of the 64 hood mold.

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Here I have a 64 hood being "Pressed"

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This is the 64 Hood right out of the mold. Made just like the "Real" one!

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The 64 hood has been trimed and fitted to the car.

Next I am "Making " the inner Hood frame out of Sheet wax. I used various thicknesses of wax to simulate the shape of the inner frame and to allow room for the hinges and latches to attach to the hood.

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This is the orientation of he full scale hood, when up.

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The hood has been Sheet waxed to simulate the inner hood frameand placed back in the mold.

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Surface coat applied to the 64 hood frame mold.

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Inside of the finished frame mold

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.031 sheet wax applied to simulate the thickness of the material in the frame.

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One "Hood Frame" still in the bottom half of the two piece mold

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Two Frames, the one on the left has been trimmed and the one on the right is mounted on a "Hood"

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Frame clamped to the hood to check for fit.

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Here I have "Painted" the back side of the mold with Adtec to insure adhesion befor filling.

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Chris filling the second half of the hood frame mold while I take the picture!

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Hood Frame mold filled, takes 48 hours to cure!

Next, here I am making the plywood framework to support the door skin molds, after I make them. Then I will wax the edges of the area of the molds, to keep the surface coat from getting where I don't want it.

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Fitting framework for Door and Headlights molds

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Left Door being molded

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Right Door skin mold curing

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Left door skin mold after removal from the Vette pattern.

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Right Door skin mold before trimming

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Fitting both door skin molds together to make one mold

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"Tweaked" door "Glass" area to get all the edges in the same plane.

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Perimiter structure and fillits added to door mold, Ready to make a "White"

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Here is the finished "White" male mold the finished one piece female will be made from.

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Right door portion of the "White"

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Left door "white"

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Getting ready to "Fill" the finished Door Molds

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First half of the door mold is finished!

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Waxing the Door Skin thickness Fo rthe second half of he mold

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Here is the second half of the door skin mold, filled and curing

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This is the finished inner door skin mold

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A set of door skins in the mold "Curing"

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First set of Door skins as they came out of the mold

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I have them all trimed and ready to add the inner door frame.

Next I will be making the Headlight buckets

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Two Epoxy Surface coats applied to headlights.

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Headlight frame and epoxy filler added to headlights. Waiting to cure!

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Headlite mold just "Popped" from the Vette

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Locating ends of the headlite "Buckets" with 4 wood blocks spot glued and melted wax to seal gaps.

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headlite "Bucket" 4 piece mold all layed up.

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First set of Headlight buckets in the mold

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Here I have them trimed, ready to add the Headlight "Doors"

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Adding "Lumber" from which I will carve the Headlight Door "PLugs"

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Carved, ready for finish fillits

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Completed head light door mold. Makes both doors at once!

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First set of headlight doors fresh out of the mold

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Headlight door mounted to a bucket and servo installed for rotation. Neat, HUH?

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