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Regarding materials...
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Posted by Jeff S. [Email] (more from Jeff S.) on Thu, 22 Mar 2007 19:11:29 Share Post by Email
In Reply to: convertible boot covers for everyone, chuck s., Thu, 22 Mar 2007 13:36:36
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I disagree on the fiberglass strength issue. Cosmetics is personal opinion, but being very experienced with laying up custom glass forms, a fiberglass boot cover would not be fragile. A cover about 1/2" thick, with that shape, would be so much stronger than the original plastic...wow! Very strong...I assure you.

I also question the price. Once the mold is done, materials alone would be $40 - $60 per cover for all the different layers of glass mat and the epoxy. And I would guess about 3 days for each one in the mold (only about 6 hours of work to saturate, roll and blend each layer - but only one would come out every 3 days unless you happen to have a huge oven). Several hundred for the mold, and several hundred for each with materials and $50/hr labor. To do a short run of 10, I'm guessing about $500 per unit. To do 100, spreading the cost of the mold over more units, would only drop the price by another $50 or so...but figure a year to put out that many with only one mold.

Long post to share that I think fiberglass would be highly impractical and very expensive. Carbon fiber is layed up using the same process as fiberglass...with quadruple expensive materials.

Question too about the stitching on the plastic covers. I've seen the boot covers with the fake stitching molded in. Mine - '91 - does not have the stitching.

One thought I've had is to have Sunbrella material (very sun resistant high-grade cloth) epoxied to the existing cover...for a more classy look. Would also go black to match the spoiler wrap-around thing.

Just my $.02.
-jeff

posted by 65.31.10...
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