[DEAD]Project Turtle: 1993 Toyota Tercel/56K=FAIL

**rdholtz** · 01-14-2009, 09:38 PM

No, don't use Bondo. Even the kind that has fiber in it is still pretty lousy stuff. It's really only meant to give a smooth finish, not add strength to a part. For anything structural, Bondo is a dirty word.

The best advice on fiberglass would come from a couple of threads in the Fabrication forum. There's a whole "sticky" thread called Fiberglassing tips, a wealth of information in Starting fiberglass sub box, and some tips in Fiberglass questions.

Nexson is a master of resin and glass fiber; he can probably advise you far better than I can. Check his threads out -- he lists materials a couple of places, as I remember.

I only have a little experience with fiberglass. I commented on your project because it sounds like a neat experiment to replace the glass fiber with paper fiber. I'm sure the paper fiber wouldn't be as strong, so a layer of glass might be needed, but we won't know without trying.

Look, "Formica" and mica products are just paper and resin with some coloring under the top layer. But mica products are manufactured in a very controlled process using pressure and heat, so the resulting product is compressed and quite hard.

I'd even like to try this myself, but I'm in the middle of a couple of other projects. Maybe later on . . . I hope it comes out great. If you choose another path, I may have to give this a shot myself some time, but it'll be a while.

I'd start by painting the inside of the box with resin -- really soaking it so it gets through to the corrugations as well. We'd have to experiment to see if the box needs support while it's curing. Once the inside cures, it should be self-supporting. Then I'd paint the outside, again soaking it pretty well. The really interesting part will be discovering how much crush strength there is when the box is cured. It may take an extra coat to make the surfaces smooth, and then you could leave it as is for an interesting look, or sand and paint.

It's fun to be a pioneer, but there's always the risk of failure. We need to remember that a lot of the pioneers ended up with arrows in their backs. Luckily, there's always the risk of success, too. And success is some very tasty stuff.

**freeflashstuff** · 01-14-2009, 10:21 PM

I had a buddy of mine tell me pretty much the same when I suggested the idea to him at church earlier this evening... He suggested fabing a box out of plywood sheets and then painting it to match the Tercel, which sounds like an easier way out, considering fiberglassing is an extreme time consuming task, but I think experimenting on some of the many, MANY boxes I have to find the right mix of resin and fiber, then if that fails, use the wood. Granted, that is a big money investment. I may post in one of Nexson's threads and see what he suggests. I think I'm gonna make a template for my box, just in case something happens in this whole indecisive state of my mind... LOL I'll fill in the blanks tomorrow in networking probably. About 9 AM Mountain time for me, IDK for everyone else, I took the ASVAB today, and my mind is FRIED!

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**rdholtz** · 01-14-2009, 10:34 PM

Originally Posted by freeflashstuff

I took the ASVAB today, and my mind is FRIED!

So you're looking at joining the military? What branch? Do you have any specialty in mind, or are you going to wait and let them make suggestions based on your test scores?

**freeflashstuff** · 01-14-2009, 10:59 PM

Yes and no. I took it as a kinda career placement thing, but depending on the results, I may consider it. What about you? Have you been in the Military?

**rdholtz** · 01-14-2009, 11:32 PM

Originally Posted by freeflashstuff

Yes and no. I took it as a kinda career placement thing, but depending on the results, I may consider it. What about you? Have you been in the Military?

Yes, a long time ago. I went into the Army in 1968. I was in the Chemical Corps stateside, and then went to Vietnam in the Engineers. In retrospect, I wouldn't trade the experience for anything, but I'd rather not do it again. Still, most of my friends are vets, and I don't think there's a better group around; it's a brotherhood.

**freeflashstuff** · 01-15-2009, 09:13 AM

Cool. My dad went to 'Nam. He doesn't talk about it much though, but I can understand why. There was a lot of crazy stuff that went down over there.

**rdholtz** · 01-15-2009, 11:56 AM

Originally Posted by freeflashstuff

Cool. My dad went to 'Nam. He doesn't talk about it much though, but I can understand why. There was a lot of crazy stuff that went down over there.

Tell your Dad I said, "Welcome Home, brother."

**freeflashstuff** · 01-15-2009, 07:28 PM

He says thanks and the same to you.

But

it appears that the fiber/cardboard has been done before and here but as we discussed, the difficult part is gonna be the balance between fiber mat and resin. Maybe the resin alone could harden the cardboard enough to not have to use the mat.... ???

**rdholtz** · 01-16-2009, 08:41 AM

Originally Posted by freeflashstuff

. . . it appears that the fiber/cardboard has been done before and here but as we discussed, the difficult part is gonna be the balance between fiber mat and resin. Maybe the resin alone could harden the cardboard enough to not have to use the mat.... ???

Since the resin is two-component, it's going to cure hard. They added fiber for additional strength because they needed structural rigidity over a large span. I think you might get away without mat for something as small and simple as a PC case. But that's admittedly only a guess, and it isn't backed up with experience. I'd probably add a layer of mat just for insurance.

In the first link you provided, he makes the point that anywhere you want to fasten, you need to add strength. You could do that by crushing a couple of fiber washers -- or even metal washers -- into each fastening point.

I think it's worth a shot. If it doesn't work, add a layer of mat and more resin. Either way, you get something unique, and a great topic for MP3Car.

**freeflashstuff** · 01-16-2009, 08:48 AM

Good points there rdholtz. I'm getting ready to go to Lubbock in about 3 hours so I get to miss my afternoon classes.

I'm going to Ignite Student Conference and I won't be back till late Saturday. I'm planning on getting some resin and trying it on a different box to figure out if just the resin will be enough. I g2g so I'll try to post from my hotel room later on tonight because as you said, this project would make a "most excellent" topic here on MP3Car.
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