Phoenix Autosport
28-11-2012, 23:29
http://www.facebook.com/phoenixautosport
Bringing a set of Renault 5 Turbo door cards back from the dead.
cards as they were recieved, fabric had been coloured black with an unknown substance and mould had set in
http://sphotos-c.ak.fbcdn.net/hphotos-ak-ash4/395091_459213040792364_1249069197_n.jpg
they were also snapped and broken in several places
http://sphotos-g.ak.fbcdn.net/hphotos-ak-prn1/59611_459212910792377_695350382_n.jpg
with fabric removed extent of damage can be seen
http://sphotos-b.ak.fbcdn.net/hphotos-ak-prn1/523584_459213160792352_1849138796_n.jpg
http://sphotos-h.ak.fbcdn.net/hphotos-ak-ash3/546802_459213267459008_196326111_n.jpg
with the card clamped together the split was soaked with resin
http://sphotos-f.ak.fbcdn.net/hphotos-ak-ash3/14361_459213377458997_923246332_n.jpg
Next the broken off section was refitted in the same way, cloth was used to back up the join and hold the resin so that it soaked into the structure of the card as it was left to cure
http://sphotos-e.ak.fbcdn.net/hphotos-ak-ash4/535_459213610792307_1255151022_n.jpg
Top surface shows where the resin has soaked through the card and has been sanded to remove excess
http://sphotos-d.ak.fbcdn.net/hphotos-ak-snc7/602378_459213427458992_681654439_n.jpg
Resin soaked join is actualy stronger than the original structure of the card so should last well
http://sphotos-c.ak.fbcdn.net/hphotos-ak-snc7/311181_459213524125649_1506520244_n.jpg
Damage around door handle hole
http://sphotos-d.ak.fbcdn.net/hphotos-ak-ash3/544743_459229450790723_2029660558_n.jpg
http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/74716_459229564124045_1357181693_n.jpg
repaired and reinforced
http://sphotos-c.ak.fbcdn.net/hphotos-ak-snc7/396196_459229660790702_127904369_n.jpg
front corner also repaired
http://sphotos-g.ak.fbcdn.net/hphotos-ak-ash3/530718_459229727457362_2047338850_n.jpg
Another crack along the front bottom corner of the door pocket repaired
http://sphotos-f.ak.fbcdn.net/hphotos-ak-ash3/21197_459229784124023_180888283_n.jpg
and reinforced on the back
http://sphotos-h.ak.fbcdn.net/hphotos-ak-ash4/486360_459229867457348_1134824182_n.jpg
top edge was badly distorted
http://sphotos-g.ak.fbcdn.net/hphotos-ak-snc7/423090_459454040768264_346316183_n.jpg
Top edge of card was sprayed with a mixture of resin and thinners then clamped flat
http://sphotos-h.ak.fbcdn.net/hphotos-ak-prn1/66268_459454090768259_874930211_n.jpg
left to soak in and cure overnight
http://sphotos-b.ak.fbcdn.net/hphotos-ak-ash4/484964_459454147434920_780980039_n.jpg
Same process was used on the bottom edge to reduce distortion
http://sphotos-a.ak.fbcdn.net/hphotos-ak-snc7/406920_459454210768247_151121756_n.jpg
resulting top edge much straighter
http://sphotos-h.ak.fbcdn.net/hphotos-ak-ash3/12896_459454390768229_564746278_n.jpg
this speaker grill tab was broken but still present
http://sphotos-c.ak.fbcdn.net/hphotos-ak-ash3/554096_459454247434910_574040153_n.jpg
repaired with resin
http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/527293_459454350768233_1181001435_n.jpg
this tab was unfortunately missing
http://sphotos-d.ak.fbcdn.net/hphotos-ak-ash3/557607_459454524101549_1696403302_n.jpg
new tab was fabricated from a couple of layers of dense card and left slightly oversize
http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/63145_459454600768208_728285650_n.jpg
tacked in place
http://sphotos-c.ak.fbcdn.net/hphotos-ak-ash3/534006_459454684101533_195105525_n.jpg
soaked in resin and left to cure hard overnight
http://sphotos-h.ak.fbcdn.net/hphotos-ak-prn1/155363_459454750768193_621475956_n.jpg
cured tab reshaped with dremmel to match the original shape and size of the tab
http://sphotos-b.ak.fbcdn.net/hphotos-ak-prn1/60777_459454767434858_197301235_n.jpg
http://sphotos-g.ak.fbcdn.net/hphotos-ak-ash4/430604_459454884101513_624977617_n.jpg
structurally repaired cards ready for epoxy
http://sphotos-b.ak.fbcdn.net/hphotos-ak-ash3/603987_459593367420998_1236141012_n.jpg
First coat of thinned epoxy applied, most of this soaks into the surface of the card sealing it and adding strength to the structure, they have then been sanded to take off any roughness left where the card surface was less than perfect
http://sphotos-h.ak.fbcdn.net/hphotos-ak-ash3/599237_459593447420990_235916929_n.jpg
after some fine filling a coat of thicker epoxy applied to allow for proper refinishing of the surface
http://sphotos-f.ak.fbcdn.net/hphotos-ak-ash3/552405_459593497420985_1622220859_n.jpg
epoxy sanded back and surface flocked in a colour matched grey flock, a vast improvement :D
http://sphotos-e.ak.fbcdn.net/hphotos-ak-ash4/406916_468096916570643_621506060_n.jpg
http://sphotos-a.ak.fbcdn.net/hphotos-ak-ash3/558970_468096843237317_540915996_n.jpg
http://sphotos-c.ak.fbcdn.net/hphotos-ak-prn1/542739_468096893237312_1347253376_n.jpg
http://www.facebook.com/phoenixautosport
Bringing a set of Renault 5 Turbo door cards back from the dead.
cards as they were recieved, fabric had been coloured black with an unknown substance and mould had set in
http://sphotos-c.ak.fbcdn.net/hphotos-ak-ash4/395091_459213040792364_1249069197_n.jpg
they were also snapped and broken in several places
http://sphotos-g.ak.fbcdn.net/hphotos-ak-prn1/59611_459212910792377_695350382_n.jpg
with fabric removed extent of damage can be seen
http://sphotos-b.ak.fbcdn.net/hphotos-ak-prn1/523584_459213160792352_1849138796_n.jpg
http://sphotos-h.ak.fbcdn.net/hphotos-ak-ash3/546802_459213267459008_196326111_n.jpg
with the card clamped together the split was soaked with resin
http://sphotos-f.ak.fbcdn.net/hphotos-ak-ash3/14361_459213377458997_923246332_n.jpg
Next the broken off section was refitted in the same way, cloth was used to back up the join and hold the resin so that it soaked into the structure of the card as it was left to cure
http://sphotos-e.ak.fbcdn.net/hphotos-ak-ash4/535_459213610792307_1255151022_n.jpg
Top surface shows where the resin has soaked through the card and has been sanded to remove excess
http://sphotos-d.ak.fbcdn.net/hphotos-ak-snc7/602378_459213427458992_681654439_n.jpg
Resin soaked join is actualy stronger than the original structure of the card so should last well
http://sphotos-c.ak.fbcdn.net/hphotos-ak-snc7/311181_459213524125649_1506520244_n.jpg
Damage around door handle hole
http://sphotos-d.ak.fbcdn.net/hphotos-ak-ash3/544743_459229450790723_2029660558_n.jpg
http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/74716_459229564124045_1357181693_n.jpg
repaired and reinforced
http://sphotos-c.ak.fbcdn.net/hphotos-ak-snc7/396196_459229660790702_127904369_n.jpg
front corner also repaired
http://sphotos-g.ak.fbcdn.net/hphotos-ak-ash3/530718_459229727457362_2047338850_n.jpg
Another crack along the front bottom corner of the door pocket repaired
http://sphotos-f.ak.fbcdn.net/hphotos-ak-ash3/21197_459229784124023_180888283_n.jpg
and reinforced on the back
http://sphotos-h.ak.fbcdn.net/hphotos-ak-ash4/486360_459229867457348_1134824182_n.jpg
top edge was badly distorted
http://sphotos-g.ak.fbcdn.net/hphotos-ak-snc7/423090_459454040768264_346316183_n.jpg
Top edge of card was sprayed with a mixture of resin and thinners then clamped flat
http://sphotos-h.ak.fbcdn.net/hphotos-ak-prn1/66268_459454090768259_874930211_n.jpg
left to soak in and cure overnight
http://sphotos-b.ak.fbcdn.net/hphotos-ak-ash4/484964_459454147434920_780980039_n.jpg
Same process was used on the bottom edge to reduce distortion
http://sphotos-a.ak.fbcdn.net/hphotos-ak-snc7/406920_459454210768247_151121756_n.jpg
resulting top edge much straighter
http://sphotos-h.ak.fbcdn.net/hphotos-ak-ash3/12896_459454390768229_564746278_n.jpg
this speaker grill tab was broken but still present
http://sphotos-c.ak.fbcdn.net/hphotos-ak-ash3/554096_459454247434910_574040153_n.jpg
repaired with resin
http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/527293_459454350768233_1181001435_n.jpg
this tab was unfortunately missing
http://sphotos-d.ak.fbcdn.net/hphotos-ak-ash3/557607_459454524101549_1696403302_n.jpg
new tab was fabricated from a couple of layers of dense card and left slightly oversize
http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/63145_459454600768208_728285650_n.jpg
tacked in place
http://sphotos-c.ak.fbcdn.net/hphotos-ak-ash3/534006_459454684101533_195105525_n.jpg
soaked in resin and left to cure hard overnight
http://sphotos-h.ak.fbcdn.net/hphotos-ak-prn1/155363_459454750768193_621475956_n.jpg
cured tab reshaped with dremmel to match the original shape and size of the tab
http://sphotos-b.ak.fbcdn.net/hphotos-ak-prn1/60777_459454767434858_197301235_n.jpg
http://sphotos-g.ak.fbcdn.net/hphotos-ak-ash4/430604_459454884101513_624977617_n.jpg
structurally repaired cards ready for epoxy
http://sphotos-b.ak.fbcdn.net/hphotos-ak-ash3/603987_459593367420998_1236141012_n.jpg
First coat of thinned epoxy applied, most of this soaks into the surface of the card sealing it and adding strength to the structure, they have then been sanded to take off any roughness left where the card surface was less than perfect
http://sphotos-h.ak.fbcdn.net/hphotos-ak-ash3/599237_459593447420990_235916929_n.jpg
after some fine filling a coat of thicker epoxy applied to allow for proper refinishing of the surface
http://sphotos-f.ak.fbcdn.net/hphotos-ak-ash3/552405_459593497420985_1622220859_n.jpg
epoxy sanded back and surface flocked in a colour matched grey flock, a vast improvement :D
http://sphotos-e.ak.fbcdn.net/hphotos-ak-ash4/406916_468096916570643_621506060_n.jpg
http://sphotos-a.ak.fbcdn.net/hphotos-ak-ash3/558970_468096843237317_540915996_n.jpg
http://sphotos-c.ak.fbcdn.net/hphotos-ak-prn1/542739_468096893237312_1347253376_n.jpg
http://www.facebook.com/phoenixautosport