For this video, we are going over the steps to create a master cylinder cover for a S550 (2015-2023) Mustang from scratch. The idea behind this video is to show you how to create parts from your imagination or even a simple modification. The steps will include creating a shape (plug), the forming a mold, then making a part.
========== Plug Creation ==========
1. Intro - 0:01
2. Background Story - 0:33
3. Step 1 (Shape the Plug) - 0:47
4. Step 2 (Sand Plug Surface) - 8:52
5. Step 3 (Clean Surface - IPA) - 9:19
6. Step 4 (Apply Primer) - 9:42
7. Step 5 (Sand Primer) - 10:32
8. Step 6 (Clean Surface - IPA) - 11:02
9. Step 7 (Apply Clear Coat) - 11:14
10. Step 8 (Wetsand Clear Coat) - 12:11
11. Step 9 (Polish Clear Coat) - 12:43
========== Mold Forming ==========
12. Step 10 (Attach Flange Material) - 14:13
13. Step 11 (Clean Off Excess Glue) - 15:41
14. Step 12 (Fill In Mold Gaps) - 16:08
15. Step 13 (Apply Mold Release Paste Wax) - 18:00
16. Step 14 (Apply Mold Release Agent) - 18:46
17. Step 15 (Apply Tooling Gel Coat) - 21:19
18. Step 16 (Layup 30gsm Fiberglass) - 23:21
19. Step 17 (Layup .75oz Fiberglass) - 24:15
20. Step 18 (Layup 1.5oz Fiberglass) - 25:46
21. Step 19 (Layup 1.5oz Fiberglass w/Wax) - 28:07
22. Step 20 (Trim Mold Edges) - 29:01
23. Step 21 (Demold Plug) - 29:48
24. Step 22 (Clean Mold) - 30:46
25. Step 23 (Wetsand Mold) - 31:09
26. Step 24 (Polish Mold) - 31:45
========== Part Making ==========
27. Step 25 (Apply Mold Release Paste Wax) - 32:29
28. Step 26 (Apply Mold Release Agent) - 32:55
29. Step 27 (Apply Gel Coat) - 34:19
30. Step 28 (Layup 30gsm Fiberglass) - 35:46
31. Step 29 (Layup .75oz Fiberglass) - 36:02
32. Step 30 (Layup 1.5oz Fiberglass w/Wax) - 36:35
33. Step 31 (Demold Part) - 37:31
34. Step 32 (Clean Part) - 38:16
35. Step 33 (Trim Off The Flange) - 38:55
36. Step 34 (Sand Edges) - 39:18
37. Step 35 (Drill Holes & Notches) - 39:57
38. Step 36 (Test Fit Part) - 41:30
39. Step 37 (Paint Part) - 42:04
40. Final Product - 43:01
Products Used:
This video contains affiliate links for which I may receive compensation.
========== Mold Material ==========
Polyester Resin (AC8040N-2K) - https://easternburlap.com/products/
Tooling Gelcoat (AC379T-2K) - https://easternburlap.com/products/
Fiberglass Mat 3/4 OZ., 50" WIDE (OC-7550) - https://easternburlap.com/products/
Fiberglass Mat 1.5 OZ., 50" WIDE (OC-1550) - https://easternburlap.com/products/
Fiberglass 30gsm, 5mx1m - https://www.ebay.com/itm/304011296765
Fill-It Clay (FILL-IT) - https://easternburlap.com/products/
Wax Surfacing Agent (AC2290-1) - https://easternburlap.com/products/
Aluminum Roll Flashing - https://www.lowes.com/pd/Amerimax-6-in-x-50-ft-Aluminum-Roll-Flashing/5001929673
Partall Paste #2 - https://amzn.to/42euVO0
Partall Film #10 - https://amzn.to/3Sa4jJa
Plastic Blank Sign - https://www.lowes.com/pd/Hillman-24-in-x-36-in-Blank-Sign/3340838
Shelving MDF Board (1701106) - https://www.homedepot.com/p/3-4-in-x-16-in-x-4-ft-Square-Edge-Shelving-MDF-Board-1701106/202089058
========== Disposable Material ==========
50-piece Sanding Discs Set - https://amzn.to/3It0POi
Chip Brushes - https://amzn.to/3UbybaC
Eye Dropper - https://amzn.to/48PZjAz
Foam Brushes - https://amzn.to/3OhpCr0
Hot Glue Sticks - https://amzn.to/427ziub
Meguiar's Ultimate Compound - https://amzn.to/3Sn29qW
Mixing Cups - https://amzn.to/3OfHFOk
Nitrile Gloves - https://amzn.to/3lABI38
Polyester Hi-Temp Tape - https://amzn.to/48Iq8Xp
Sanding Drum Set - https://amzn.to/3EcSYSp
Sandpaper 60 to 5000 Grit - https://amzn.to/3u3M8g7
Wood Sticks - https://www.walmart.com/ip/Go-Create-Super-Jumbo-Craft-Sticks-45-Pack-Extra-Long-Wood-Craft-Sticks/47426780
========== Misc Products ==========
Applicator Pad - https://amzn.to/47PewAG
Glue Gun - https://amzn.to/3XOqXrm
HVLP Spray Gun - https://amzn.to/3OmsjI3
Respirator Mask - https://amzn.to/3SFpg04
Step Drill Bit Set - https://amzn.to/47XiU0v
Trim Removal Tool Set - https://amzn.to/3hRQA8j
Tools:
Applicator Pad
Center Punch
Circular Saw
Gelcoat Gage
Glue Gun
HVLP Spray Gun
Isopropyl Alcohol 91% (IPA)
Jig Saw
Microfiber Cloth
Oscillating Tool
Popsicle Sticks
Rotary Power Tool
Safety Glasses
Sander
Sandpaper (80-2000 Grit)
Shop Towels
Stepper Bits
Trim Removal Tool Set
Utility Knife
#Fiberglass #MoldMaking
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