orphancars
orphancars Reader
12/23/10 12:27 p.m.

I didn't want to add this to the box flares discussion -- just wanted to add another way to add flares to a car.

A little background -- I needed fender flares added to my TVR to cover the 315's and 17 x 11 inch rims. It was simply not possible to narrow the suspension enough (C4 IRS) to get suspension/wheels/tires inside the bodywork of a narrow British car. So I started looking around for a set of flares that might work or could be adapted with little effort. FYI....there is no off the shelf part for a TVR flare

In my case, the answer was curiously enough, Miata! Moss Motors carries parts from AWR. The Flares for a late model Miata were a very close fit. The fronts, swapped sides, were a good match for the rear, and vice-versa for flares for the front. The only issue seems to be that the Miata might have some more curve to the body whereas the TVR is a little slab-sided. The flares stuck out from the body at the leading edge -- they also overlapped the door a bunch.

I got them to fit the best I could -- and they did with very little trimming. I cleco'd them to the body and epoxied them to the body at the rear and where they touched the body under the door. I then notched out the flares so the doors would open/close. I also spent a lot of time making sure the flares were symmetrical side to side, and that they didn't interfere with the wheel/tire under full suspension compression.

Now the fun began. I had gaps where the flare just wouldn't meet the body at the leading edge behind the doors, as well as at the peak of the flare. TAP Plastics makes this cool stuff called X-30 expanding foam. I love this stuff!!! Mix equal parts, wait less than a minute and the liquids expand to 30~40 times their volume in about 3 minutes. Foam is fully cured and ready for shaping in less than 30 mins! I shaped the foam with nothing more than a japanese pull saw to rough out the shape, then sanded to shape with a sanding block and 1 sheet of 60 grit sandpaper.

Pics show a before and after. I'm just waiting for the weather to warm up a bit before I start to glass over the foam.

I think this is a slighty quicker route than trying to mold the entire flare from scratch -- and I started out with a pair of flares that were symmetrical -- something I was not so sure I could pull off from scratch. I did find out that the fine British handiwork of the 60's and 70's did induce some variation side to side on the car.

mndsm
mndsm Dork
12/23/10 12:27 p.m.

Great Stuff solves many problems.

orphancars
orphancars Reader
12/23/10 12:44 p.m.

It isn't great stuff -- it won't stand up to epoxy/polyester resins -- it will just melt!

The X-30 is good, only problem is that it doesn't dissolve like other molding foams. What I plan on doing is just doing 1 'glass layup over the foam, remove that layup, then cut/dig/sand the foam out, replace the 1 layer and 'glass in on the front and backside.

orphancars
orphancars Reader
5/20/11 8:20 p.m.

Small update -- still working on the flares -- and the X-30 foam gave me a few ideas -- used it to raise the center of the hood to clear the top of the engine, and also using it up front to give the ol' TVR a little rhinoplasty. Of course now I have to start glassing all of this work in.....just in time for the weather to heat up in Texas!

First pic -- you'll see hash marks all along the front -- using points on each side of the center of the bonnet to make sure things are symmetrical from side to side.

And now the pics....

John Brown
John Brown GRM+ Memberand SuperDork
5/20/11 8:25 p.m.

nice

Maroon92
Maroon92 SuperDork
5/20/11 8:27 p.m.

That looks pretty wicked!

Taiden
Taiden Reader
5/20/11 9:31 p.m.

LOVE

orphancars
orphancars Reader
5/20/11 10:32 p.m.

Thanks for the comments -- it kinda helps keep me going!

One thing before anyone points it out .......yeah, the radiator intake isn't exactly symmetrical yet. Noticed that after I cut the shape out of the foam. Currently working on it -- using a little old bondo that has thickened up a bit to build up the shape and make it the same side to side. Once all that is complete I glass everything in and then remove any foam/bondo/temp 'glass from the backside and lay in a couple reinforcing layers of new 'glass/epoxy. Just learning as I go......

carguy123
carguy123 SuperDork
5/20/11 10:33 p.m.

Just found out Jeff and I are almost neighbors. I get to go over and see the project in person.

gamby
gamby SuperDork
5/20/11 11:43 p.m.
Maroon92 wrote: That looks pretty wicked!

I came in here expecting a joke thread about some rolling abortion. Never expected to see this mean machine. Nice work!!!

fast_eddie_72
fast_eddie_72 Dork
5/21/11 12:21 a.m.

Bad

fast_eddie_72
fast_eddie_72 Dork
5/21/11 12:21 a.m.

Ass

Woody
Woody GRM+ Memberand SuperDork
5/21/11 12:46 a.m.

My new favorite TVR.

DWNSHFT
DWNSHFT Reader
5/21/11 2:10 a.m.

Your boldness is admirable! Way to tackle the job!

David

Javelin
Javelin GRM+ Memberand SuperDork
5/21/11 7:56 a.m.

Love it!

DrBoost
DrBoost SuperDork
5/21/11 2:25 p.m.

Wow man, nice work. That's a great looking car stock. Despite the quite substantial flares the lines are preserved and the car still looks great.

JeffHarbert
JeffHarbert GRM+ Memberand Reader
5/21/11 5:19 p.m.

Very nice work. Gives me a few ideas...

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