- 1). Study the designs of body kits from various retailers to get a basic idea of how you would like to design yours. Carefully take the dimensions of the areas that the body kit will connect to your vehicle to ensure a good fit. You should pay attention to the dimensions of the kit, especially length, to keep from interfering with the wheel well.
- 2). Sculpt the foam block into the exact dimensions and specifications of your design. Use a knife or a razor blade to cut the large pieces out, and sand with 180-grit sandpaper to remove any unwanted bumps. Cover the foam with Bondo and allow for it to dry for two hours. Once dry, use 220-grit sandpaper to sand down any bumps on the Bondo.
- 3). Spray three coats of polyester primer directly on top of the Bondo and let it dry. Read the direction label carefully for proper drying times. Sand the dried primer down with 220-grit sand paper. Sand with finer and finer grits until you have wet-sanded with 1,000-grit sandpaper. Allow the mold to sit for three days. During the three days, wax mold it once a day to ensure a smooth surface for your body kit. After the three days, cover the waxed mold with tooling gel and allow it to get tacky.
- 4). Brush the resin directly on top of the tooling gel in an even coat. Try to apply the coat as evenly as possible --- any chunks or clumps may compromise the structural integrity of your body kit. Break up the fiberglass mat until you have separated fiberglass strands. Lay the fiberglass on top of the resin. Follow this step six times for a thick body kit.
- 5). Allow the resin to dry. Drying times will vary according to the manufacturer of the resin, so read the directions on the label carefully. Once dry, use a wooden mixing stick to pry the body kit off the mold. Shave the protruding fiberglass strands with a razor.
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