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Level Motorsport M86 Build - Rocco

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  • After the holes are drilled, I smooth out the inside of the holes so they don't score the dimple dies, and they don't cut your finger if you stick it in there for some reason.
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  • After the roof has been buffed and waxed, a layer of PVA mold release is applied. PVA is like liquid Saran wrap. It keeps the gel coat from melting the wax and eating into our paint as it cures, and helps release the mold from the panel when finished. It is water soluble, so it is wash off of the finished mold with soap and water.
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  • After the thin layer PVA is dry (typically 10-30 minutes), the gel coat is generously applied. The gel coat is allowed to dry 6-12 hours before the first glass coat is applied.
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  • After achieving a tight fitment on the notch, we bevel the edges of the connecting tube so the weld grabs the full thickness of the tube material, in this case 0.095 DOM tubing.
  • Plinth boxes with base plates ensure that the cage stays where it belongs. The plinth attaches to the floor, but also to the rocker panel. In unibody cars the rocker is multiple layers, and the floor is typically thin, so welding only to the floor creates a greater chance of the cage punching through. Being welded to multiple planes also makes it stronger, even if the MIG welds are gross.
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  • Some panels are molded in place so there is no chance of them distorting or being damaged during removal. This is the gel coat on the roof. It takes on any characteristic of the material below it, so the panel has to be perfectly clean and smooth before the mold making process is started. The gel coat will even pick up 400 grit sanding marks, and that would be transferred to your finished part, so the panel being molded has to be PERFECT.
  • The B pillars were notched slightly to make room for door bars, then reinforced with dimpled sheet metal to restore them to their factory strength, or stronger.
  • Gel coat. A ton of gloves are necessary when working with resins, fiberglass, and carbon. It can be a messy job.
  • Properly mixed two part components are very very important. One bad mix can ruin an entire mold or part. A low speed mixing drill is used so the material doesn't cavitate.
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  • We use two types of chopped strand fiberglass for our molds. .75 ounce and 1.5 ounce. The "weave" of the lighter material is less dense, so it conforms to complex shapes more easily.
  • They cut just over enough fiberglass to cover the panel they are working on.
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