Ha wondered why you was so quiet recently.
Yeah the focus st needed a bit of help with a few things. If you know the mk2 focus, it has a stupid bonnet release system they the grill badge. Mine broke 9yrs ago and have been using a modded long screwdriver. While doing the headlight shining , I had a thought to use a 1/4 socket uni joint and extension to the badge and make a tab at the front to twist the rod that opens the latch . Way better than the plastic Ford part they supply.

The bulkhead mold was propped up to simulate how it'll rest in the car , the actual fglass part once made will have a slight flex so it should fit fine , and after heat from engine compartment it'll settle down to fit nicely.

Whelp looks like the person who supplied the original cover is getting a nice shiny fiberglass one !
 
The positive is mold looks fricken great though!

This is absolutely awesome, I can't wait to see how it comes out Marty.

A bit more on the bulkhead cover today, I did get it glassed up and took about 4hrs, slightly longer than I thought , as this is a test pilot part being first off until satisfied with fitment and how strong it'll be. Speaking of which I seen the UK ones and look like you can park a LandRover on them, very unnecessary as it's not a load bearing item. My plan is to have them solid enough but still flex a little of needed..

I'll test this one on my unmolested car just to make sure it's all good.
Had a cup of resin left over so finished off making the 6 dial mk1 dash fascia mold, this is mainly for my project which I'll show later on in the build

My car won't be running stock dials but I want it to be close though not race inspired and the dials can be hooked up with the ECU if required.
On a side job, I've had a go at plastic welding of a grill for my ute, it had a crunch on the corner deforming the shape, that was adjusted with the heat gun and the little plastic weld staple gun did pretty good , it's holding up good .

Look at the ingenuity! It looks great and you're right, once it's painted in semi* you would never know unless you were told!

So if I understand correct you'll make another mold off of this part once you have it sitting nice using the heat gun and a bit of persuasion? Seems like a solid plan.

Started on another mold, this is a revamp of the mk1 rear parcel shelf, my original mold was fine except the part was best covered on fabric, not now cause it's got texture like original. Decided to use white 2pk this time , same result for the mold

Also got some more done on the rear door cards so that the speaker mesh covers will fit tightly , they will be glued in place once the trims are tidied up


I'm also working on a mk2 dash pad , I happen to have a whole dash panel to bolt it to so the shape is correct, this shows how wide a sedan crash pad is to a van dash panel

I marked out where the best places are to cut the heater cover so it sits better on the bulkhead. Testing it on the original mk2 , I put small fglass squares on the back to act as glue , I'll see how I went with it tomorrow. You can see where I marked it to be cut

Thanks Mark, yeah fglass is an art form but once the tips and tricks are known it's like riding a bike but messy!

If I could've fitted the original to a car while laying fglass on wouldn't been the best way, but since the original was cracked and my 'repair for mold' fixes could break I just took an uneducated guess at the shape. I'll be out there soon to check how my cut n shut worked.

The original part has a full foam (soft foam) with plastic lined outer, it was thick in places but I suggest to just use a handful of foam pads in places to keep it from scratching or rattling.

Nothing happening on the heater cover this week, I've started on a different part.
The dash top for mk2, a long time coming so thought to make a start while I'm in the mood of fglass jobs . The dash top I bought from a guy interstate cheap but he'd skinned it and used spanda foam to fill cracks etc. My first part is to to brush resin over the whole top and glass on a layer of thin woven material similar to surfboard matting
This pic is from a week ago

And now it's been flat sanded with a few layers of filler to bring back the shape closer to original

Having a spare metal dash panel really helps keep things in check.
One thing I'll need to do to make the part come out the mold is I can't have any part of the dash exceed 180deg hook or I'll need to make a separate bolt on edge like the heater panel has .

Plenty of filler to flat back and radius the shapes, the tin of filler I have was getting a bit hard so I done the American trick of adding a bit of polyester resin and mix it through, as both filler and resin needs mekp to start the setting process off, it's totally fine and added resin actually strengthens the filler..