Resin, in principle, the standard thing, but the resin of different firms may be quite different from each other in quality. The properties of resins and their operating parameters rather strongly influenced by the temperature characteristics of the room in which work, and ventilated.

Sometimes for better hardening matrix with the product is placed in a special drying chamber. This helps to significantly speed up the process of obtaining the finished product. Most durable products are manufactured in an autoclave under high pressure and high temperature.

As mentioned above, the resin - not as sturdy material, and fiberglass act as a reinforcing material. Fiberglass and come in a variety of thickness, and structure. There are two basic types: fiberglass and fiberglass. Fiberglass consists of randomly arranged fibers, and fiberglass looks like a normal fabric. The greatest hardening yield different brands of fiberglass. Fiberglass give lower strength, but they are easy to process and compared with glass is better repeat the form of a matrix.

Fiberglass can be very thin air (this material is called a stack-lovualyu), and is thick like a blanket. Fiberglass vary in thickness and density, but share their weight per square meter of material in grams: 300, 450, 600, 900. Steklovual with a density of 32 g / m allows us to derive the surface is very high complexity, with many facets and sharp transitions. Throw pillows (600 or 900) allows you to dial thickness of a product and achieve the required strength. It is worth noting that creating a thick products work takes place in several stages. Laid out a few sheets to produce the first layer and is given time to freezing. Then, additionally, already on a hard surface, additional sheets stacked mats to give the required thickness. If you try to put right all the layers, then it is likely that the finished product warp, "spoiled".

Fiberglass (sometimes referred to as the characteristic netting "mat") come in different thickness. These fabrics are also used to stiffen and the volume of the finished product. As with any fabric, glass works differently in different directions when stretched. Therefore, to give the necessary rigidity fiberglass is laid at different angles. Quality Glass also plays an important role. It should be well impregnated with resin and keep it between the fibers.

To make the products with large planes of strength and stability, as well as to reduce the weight of the finished product using special inserts made of special material - polycor. Polikor - a nonwoven fabric of continuous polyester fiber, containing in its structure mikroballony. This material is placed between several layers of glass mat. Often polycor affixed only reinforcing strips, rather than large sheets. Speaking of strength. Strange as it sounds, but the less resin in the fiberglass (assuming full saturation and the absence of bubbles), the stronger will be the finished product and the less will be its weight.

One often hears about the cars with fiberglass bodywork elements that are resistant to scratching, as painted in the mass. It's not quite true. You can scratch them, but the color will remain. This happens because the manufacture of parts with quality surface initially in the matrix is applied decorative layer of special material - gelcoat (gelcoat - ge-left cover). This polyester composition and free products from further painting. You can pick the color, or create your shade tinting compositions. In addition, gelkoatny layer increases the life of the product, protects against environmental influences and obscures the structure of fiberglass. Once the gelcoat is dry, laid fiberglass and resin. The finished product will have a flat (depending on the quality of the matrix), the color surface.

In this process lies an important point. If the layer of gelcoat is in one place too thin, it can happen as follows: or in this place will shine through the structure of fiberglass or gelcoat can generally move away and frowned. It is therefore essential to use the right materials and follow the technology. For the uniform application of gelcoat is often used brushes and spray guns. So can significantly reduce the number of marriages. But for spraying gelcoat should be more liquid than for manual application.

LAYOUT AND MATRIX

For manufacturing products made of glass the first thing to - to create its layout. Actually, the layout is always needed, but a one-time work is sometimes possible to lay fiberglass on the temporary braces. This approach works only when there is no need to create quality surfaces. For example, very often in the manufacture of new door panels are made of fiberglass based directly on the door, protecting her first film paper adhesive tape, polyethylene, wax, etc. Poor quality of the surface in this case, few people care about, because then this solid fiberglass kovuyu-crust glued porous material, and it leather, cloth or something else. Manufacturing techniques of body and decorative items made of glass and those items that will be replicated, is somewhat more complicated. Can not do without prototyping and matrixing.

Layout of the future product can be manufactured in various ways: plywood, clay, polystyrene, etc., from how well made the layout will depend on the quality of future products. Moreover, if necessary, to ensure the details, which will then be created, was perfectly smooth surface, over the quality of its work will have on the layout. The more sleek and smooth to the layout, the less work will be required later, during manufacturing and bringing the matrix.

Even before creating the layout is necessary to understand whether you can make a whole piece or not. The fact is that when working with fiberglass and similar materials needed to finished parts after hardening could pull out of the matrix, nothing damaging in this case. Perhaps, the item will be configured so that it will have to be made of several parts, and then bind them together, but vykleit ball through the eye of the coal is unlikely to succeed.

Matrix created by the layout. This is the most crucial moment. First of all, the layout voschitsya, ie, coated with a thin layer of wax. This procedure can be likened to polish the car. Once the layout has been prepared, it is applied a layer of a special matrix gelcoat. This coverage will further allow to deduce the surface of the matrix is almost a mirror. Matrix gelcoat is thicker than usual, and lies a thicker layer.

After you get up this layer, starts laying glass mat. First-thin steklovual. She would like to repeat all the curves and contours of the layout. Further, it is desirable to dry out the first layer. Only then can put a few more layers of a thicker mat, but immediately dial thickness is not necessary, otherwise the matrix could lead (to bend and warp). When you create a matrix into simple parts can simplify the procedure. The main thing - experience.

If the matrix is loosely, then for its manufacture are made special wall around the layout, dividing it into segments. Laying out the main, after the freezing walls are removed and by treating the edge of the first segment of the matrix, laid out the rest. For correct positioning of the segments relative to each other in the first made in forming a special pit. When will you be molded following segments, these pits are filled with resin and fiberglass, and there will be bumps. These couples and allow for future use properly fasten the various parts of the matrix together. For the bond segment of the matrix at the edges of all parts of drilled holes for bolts. For a matrix has been strong and well keep in shape, after it was made before remove the layout, the matrix priformovyvayut ribs. Depending on its size it can be a durable steel frame or a small plywood or wooden ribs. Ready-matrix, if the layout was made carefully, and may not require further treatment, but often have to remove the surface, ground and polished to a shine matrix. Only then can we get the perfect item. And to the bodywork elements generally need special attention.

Then begins the long process of waxing. Matrix has to carefully rub the wax a few times with interruptions. Wax should not just dab and rub until a thin, smooth, invisible film. If you do not, then the surface of the finished product will not be smooth, and rough.

After, and sometimes instead of waxing sometimes use a special liquid, which dries, creating film coating that prevents the ingress of resin or gelcoat on the matrix, which can not be avoided. As it is impossible and scratching its surface. Otherwise, the resin can be "tightly" adhere to the matrix, and then the procedure grinding, polishing and waxing have to repeat again. Sometimes use special formulations, which processed the matrix can be removed from it up to 100 items, but good old-fashioned wax is always the most intuitive and reliable means.

The process of creating a matrix, described above, is a fairly common option used by most aftermarket companies, but this does not mean that there is no other way. There are computer technology, machines, allowing for a virtual model cut from any material of any layout or ready-made mold or matrix. But this is an industrial, not the garage level.

Actually, we may begin to manufacture parts. Gelcoat layer is in principle not required, but, firstly, it gives a more complete form the finished product, as well as color, can save on painting or even to refuse it, and secondly, it protects the matrix from the fiber, which is actually even very abrasive, ie, scratching.

TECHNOLOGY

Technologies for production of products from glass, there are several. Not immediately stipulate that these methods are used and when used with other reinforcing materials such as carbon fiber, Kevlar, and other woven materials, and combinations thereof.

Manual (contact) molding. This method is the easiest and cheapest (not counting the cost of skilled labor). Impregnation of glass fiber by roller or brush, which should be resistant to the resin. Fiber or just fit into the form, or after impregnation. Processing of glass stakeout rollers facilitates a better distribution of resin between the fibers. Then ukatochnymi rollers produce a final rolling fiberglass, squeezing out air bubbles and evenly distributing the resin throughout the volume. It is extremely important not to allow under a layer of fiberglass air bubbles remained. If the product hardens to such a marriage, this place will be reduced down to a possible through-punching. Such brachki also may prevent further processing of products, to demand its restoration or complete replacement. In any case, will be spent additional materials, labor and money.

Manual method may be somewhat mechanized. There are mixers, feed the resin with the catalyst through the cushion, and other devices. But ukatyvat still have their own hands.

The dignity of manual method is quite obvious: a simple and cheap. But any savings could have a downside. Quality of finished products is highly dependent on the skills of workers. And the working conditions in such an approach quite harmful. In addition, it is very difficult to achieve high performance. However, for small firms and small amounts of this method is most appropriate.

The method of spraying chopped rovvinga. This approach is far more technologically. It uses no glass, and Steklonit, which is served in a special chopper gun, which is chopped into short fibers. Then the pistol spits "them together with a portion of the resin and catalyst. In the air, all mixed and applied to the form. But after this procedure is still a lot to prikatat to remove air bubbles. Further hardening occurs as usual.

This method looks very tempting and easy. Seemingly simple and hose. But there is one drawback, because of which this is not so popular - too much consumption of resin. The product obtained is very heavy, and as the fibers are intertwined with each other, the mechanical properties of the glass a little bit worse. In addition, harmful vapors resin is mixed suspension of fine particles of glass from the chopper, it is very harmful to human lungs.

The method of winding. This particular method is intended for the manufacture of hollow round or oval section components such as pipes or tanks. Thus made sailing masts, fishing rods, bicycle frame, car mufflers, etc., are passed through a fiberglass tub with resin, then through the tensioning rollers, serving to tension the fibers and remove excess resin. The fibers are wound on a core with the necessary cross-section, winding angle is controlled by the ratio of the speed of the trolley to the speed of rotation. How to wrap a thread on the bobbin sewing machine. The result is strong and lightweight products.

And the advantages and disadvantages of this method are very close. They do not make a car fender, but make the mast of a ship or even kardan in other ways no less difficult.

The method of prepregs. In this case, are not used some resin and fabric, and the so-called prepregs - pre-impregnated with resin fiberglass. Glass fiber pre-impregnated with resin predkata-lysed under high temperature and high pressure. At low temperatures, such blanks can be stored for weeks or even months. In this case, the resin in the pre-Prego is located in semi-solid state. In forming prepregs stacked in a matrix and close the vacuum bag. After heating to 120-180 ° C resin becomes fluid state, and the prepreg under vacuum takes shape. With further increase in temperature of the resin hardens.

The whole problem of this method is the need of heating equipment, especially autoclaves. For this reason, to produce large parts very difficult. But the advantages are obvious. Using a vacuum can significantly reduce the likelihood of air bubbles and significantly reduce the proportion of resin in the finished product.

There are other technologies - bullet-TRUS, RFI, RTM, etc. - almost all occasions. The choice of a technology depends on the required volume of the product and the amount of money from the organizer of such proceedings.

CONCLUSIONS

What gives the fiberglass? First of all - the weight. And although the creation of a truly hard part sometimes has to make them thicker, and this extra weight, but, unlike steel or aluminum, fiberglass able to return to original shape after impact, not entailing the destruction of the item. And the repair parts from fiberglass concept of "body-AE" takes a slightly different meaning. Minor cracks can be sealed within the resin overlay sheet or fiberglass mat. A lot of damage can be restored by replacing the part again in the matrix and restored the order of the desired segment. But this method may not give good quality, and likely damage to the matrix, and this can not be avoided. Simply make a new element. Although fiberglass parts can be restored and the old-fashioned way: putty, putty knife, sandpaper and water.

The disadvantages include the high cost of materials. But what's the worst, most toxic. When working with this material is extremely important to observe safety precautions. It is advisable to use a respirator, as a pair of epoxy resins quite unsound. Whatever it was, fiberglass, and to this day remains the most popular material world of tuning. And while a variety of Kevlar, carbon fiber, polyurethane foam, basalt fiber, etc., are becoming stronger than its close, I think that fiberglass it will still be in demand.