How to make a twin pillar pod G7

Hi

The guide for this month requires some skill, some money and will to finish something, also for fills a need.

If you have not guessed yet, I will be showing you how to make a pillar pods from start to finish, as you may be aware you can not get hold of the pods for RHD cars but you can for LHD so hence the project.

Tools needed,

• Dremel
• Sand paper
• Gloves
• Knife/blade

Consumables

• Time (Depends on skill)
• GRP kit
• Flocking (not essential)
• Yellow filler primer
• Polymer based filler
• Sand paper & wet and dry
• Black finishing paint
• Pods (ANY)

1; Remove your pillar - this just pulls off

2; Go out or ebay a pillar pod (i used a saxo one) any will do

3; Trim the pod down so it sits correctly on your pillar, doesn't need to fit 100% and it can look tatty just so long as you get the lines correct

4; Go out to your car and check the position for the drivers point of view, if your happy with this then tape this into place, best to use electric tape

5; Using your GRP kit layer a rough joint between the two and let it sag in. to use GRP just hold it in place a brush the glue over it and let it dry for a day. keep doing it until the grp is stuck well and no big holes are left. ( you can remove tape prior or just leave it)

6; Using a polymer based car filler, start the process of blending, this is where it takes time, be sure that before you start you sand the plastic and GRP to give a smooth (ish) layer but something to bond too. let it dry and sand until you have a smooth pod. leave a day between filling and sanding.

7; Use a filler primer to remove any silly little marks it any! 3/4 coats.

8; Let it dry and examine in the light to see any imperfections.

9; If you intend to finish your pod in a dark colour give the pod a black paint.

10; At this stage get your drimmel out and cut away the back so you can get your wires through. you can do this prior to painting but I think its best left toward the end! TAKE YOUR TIME.

11; This is the finishing stage, I recommend you use flocking as you get a lovely furry finish which is easy but again time consuming, if you choose paint try not to use your car colour as you will get glare but this is up to you! I would also suggest mat black paint. I have used flocking, and as shown in a wet state. NOTE I have done both sides to match.

12; Look at it and install into your car, again look at it and then question if you need to flock the whole car??

On request, a flocking guide.

Flocking is like no other finish it can best be described as a vlevet like surface and can be applied to any solid surface, metals, woods, plastics, textiles, glass ect, with minium preperation. Todays modern flock is made from hardwearing, long lasting nylon and give a professional finish on all materials.

NOTE: when flocking you should always have a mask to prevent inhaling the flock or adhesive!

Preperation;

The surface must firstly be treated for removal of grease and oil. You should fill all gaps and holes you do not wish to see and in many cases it is good practice to rough the surface prior to flocking. this will give a good adhesive bonding surface.

Application;

Simply paint the surface with the adhesive, ensure that the surface is covered and the adhesive is a uniform thickness (I advise you use a cheap or old paint brush) The flock should be placed in a container (similar to the squeezy ketchup bottles) hold the bottle of flock about 20mm from the adhesive on the surface and squeez the bottle hard, you will need to shake the bottle every now and then! Keep squeezing hard untill the surface is covered. Leave the item to dry for 24hours and then using a dry clean paint brush, brush the excess flock off, you can re-use this flock so put this back in the bottle for later. If you have missed areas it is possible to put adhesive back on the area and flock over without leaving any blemishes.

Hope this helps and shows how easy it is.

I suggest you use this company frost

Please follow the guide carefully, If you rush the job you will end up with utter-crap! take your time and take it easy. This will take a few weeks if you have commitments, its best to do something then leave it till the next week for the next step IE sand and fill then leave and so on.

I will not take any responsibility for your actions nor will CCUK, do not sniff the GRP glue or try and drink it! Read all precautions on all objects purchased and handle with care. Do not attempt to do this inside over the carpet your mom (if living with parents) will throw you out and the misses will divorce you or shout quite a lot I feel. If you live on your own and don't care then it up to you, unless you have a mad land lord.

Do NOT think this will be easy you will need to give this project love and detail to end up with a good finished project! Saying that its a good learning curve if you don't know what your doing and will teach you a lot about blending and bonding also GRP. Its something to be proud of.