Ivan's coupe: roof stuccowork

[Ivan141]

Small update.
I took the extra roof supports home so I can properly shrink the curve into them
on the shrinker/stretcher.. Hope to be bringing those back to the car beginning of July and then make some appointments to get the bodywork done.

In the meantime there was something really bugging me. Lennert (Robokill) once kindly let me have one of his original kouki coupe spoilers (along with a trunklid), and it has been sitting in my basement for years. When I pulled it out this year I found one end of it had broken off completely. These things cost like 400 euro new these days.

So a small side project: try to salvage an original spoiler (cause I like the look of it).
Plan of attack:
-use spray foam (PUR) to fill up the damaged area
-use rasps and saw to shape the foam
-filler over the foam for final shaping
-laminate a layer of carbon over the whole thing to make it solid.





So far I've gotten the first 'glue' layer of epoxy on and stuck the carbon twill to the spoiler. It's not gone horribly, but there are 3 spots where the weave is not super pretty.. on the corners it is really hard to bunch that stuff together without it forming pleats (not surprising). In the middle of the backward facing edge of the spoiler there is also a small wonky patch, but I think I can live with all this.
Next up is layering on at least 3 or 4 coats of epoxy and sanding everything smooth.

Also need to fix the inside as half the tabs in there have broken due to captive nuts being rusted to the bolts. Think I will just put stainless steel strips in there with studs welded to them in stead of captive nuts.. epoxy those in there with some carbon and call it a day. The original mounts never work out well unless regularly maintained (and lets be honest who does that?).