Alexei Volkov
Fender flares can be made from a variety of materials, including plastic, rubber, and fiberglass. One popular method for moulding plastic fender flares involves using a heat gun to mould the plastic into the desired shape. Another method is to use spray foam to build up a block, which can then be shaved down and shaped before laying fiberglass over the mould. When attaching fender flares to a car, it is important to consider the flexibility of the part and choose an appropriate adhesive or filler to prevent cracking. Some car owners choose to use a combination of glue and rivets for a secure fit. Sanding and painting are also crucial steps in achieving a smooth and seamless finish for the fender flares.
| Characteristics | Values |
|---|---|
| Adhesive | 3M panel body adhesive |
| Additional security | Rivets |
| Sanding | Sand to bare metal |
| Filler | Flexible and plastic body filler |
| Primer | Primer |
| Paint | Paint |
| Filler for imperfections | Spot putty |
| Alternative filler | Flexible putty filler |
| Alternative adhesive | Double-sided 3M tape |
| Alternative process | Cut off wheel arches, fill the gap with foam, and lay fiberglass |
| Alternative material | Fiberglass |
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What You'll Learn
Use glue and rivets to attach the fender flares to the body
Before attaching the fender flares to the body, it is important to clean all areas of the body where the fender flares will make contact. Use a good bug and tar remover and a scrub brush to remove all stuck-on gunk. Ensure the fenders are dry before installation.
If you are using decorative rivets, insert the bolts (with a washer around them) through the pocket holes on the outer side of the flare. Thread a nut around the bolt on the reverse side of the flare to secure it. Repeat this process until all rivets are in place.
If you are using glue, apply a 3M panel body adhesive to the fender flares and the body. You can also use existing rivets to add extra security.
Once the glue is dry, you can start the sanding process. Sand the area to bare metal and apply a flexible and plastic body filler, mainly onto the flare so that the regular body filler will adhere better and not crack off as easily.
After sanding, apply the regular body filler and follow the contour lines of the car. Once you are satisfied with the body work, you can primer and paint.
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Sand the area and apply a flexible body filler
Sanding the area and applying a flexible body filler is an important step in achieving a smooth and seamless finish when moulding plastic fender flares. Here is a detailed guide on how to do it effectively:
Firstly, it is crucial to prepare the surface by sanding the area to bare metal. This step ensures that the plastic body filler will have a clean and rough surface to adhere to. Use a DA sander with an appropriate abrasive disc to remove any paint or coatings from the repair area, extending beyond it by 2 to 3 inches. This extra surface area will provide a suitable workspace for the flexible filler.
Next, clean the repair area thoroughly. Use soap and water, followed by a VOC-compliant surface cleaner, to eliminate contaminants. A dedicated microfiber detail cloth for each cleaning agent will help ensure a spotless surface.
Once the surface is prepared and cleaned, it's time to apply an adhesion promoter. This step is crucial as it ensures that the flexible body filler will adhere securely to the sanded area. 3M recommends using their Polyolefin Adhesion Promoter, applying it evenly with a light coat to the repair area, including all bare plastic surfaces. Allow the promoter to dry for approximately 5 to 10 minutes before proceeding.
Now, it's time to apply the flexible body filler. Choose a suitable filler, such as 3M's EZ Sand Multi-Purpose Repair Material. Using a manual applicator gun, start by applying a "tight coat" of the filler to fully wet out the substrate with adhesive. This initial coat ensures the filler will bond securely.
After the flexible body filler has been applied, it's important to allow it to cure according to the manufacturer's instructions. This curing process will ensure that the filler is strong and durable before proceeding to the next steps, which may include additional sanding and the application of regular body filler to achieve a smooth and seamless finish for your plastic fender flares.
Remember, when working with any automotive repair materials, always refer to the manufacturer's instructions and take appropriate safety precautions, including wearing protective gear such as gloves and eye protection.
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Use spray foam to create a mould for the flares
To mould your own fender flares, you can use spray foam to create a mould for the flares. This process will require careful planning and attention to detail.
First, you will need to cut a strip of hardboard and screw it to the underside of the fender. This will form the shape around the wheel rim and create a base to work on. Next, use masking tape around the fender to prevent the fibreglass from sticking to it.
Now, you can start to build up the shape of the fender flare using spray foam. Spray the foam onto the hardboard base and let it expand and cure. You may need to apply multiple layers of spray foam to achieve the desired thickness and shape. Once the foam has cured, you can sculpt it to the final shape using a saw or a knife. Be warned that spray foam produces a lot of dust, which can be toxic, so wear a mask and eye protection.
After sculpting the foam to the desired shape, you can lay fibreglass over the foam mould. This will create a smooth surface for the fender flare and help to strengthen it. Finally, remove the fibreglass from the foam mould, and you will be left with a fibreglass fender flare that is ready to be painted and installed on your vehicle.
Using spray foam to create a mould for fender flares is a relatively simple process, but it requires time and patience to achieve a satisfactory result. With practice, you can create custom fender flares that improve the appearance and functionality of your vehicle.
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Smooth out the mould with a heat gun
When using a heat gun to smooth out a mould, there are a few important steps to follow. Firstly, it's crucial to understand that different types of plastic have varying responses to heat. For instance, thermosetting plastic cannot be remoulded once it has been heated. Therefore, it's important to identify the type of plastic you are working with before applying heat.
Once you have confirmed that your plastic fender flares can be remoulded, you can begin the process of smoothing out the mould with a heat gun. Start by slowly running the heat gun over the surface of the plastic. Hold the heat gun a few inches away from the plastic and move it back and forth to evenly distribute the heat. You will need to do this for a few minutes until the plastic starts to soften and become pliable.
To check if the plastic has reached the right temperature, use a pot holder to gently press down on the surface. Be careful not to burn yourself! If the plastic is soft and pliable, you can continue to the next step. If not, continue heating the plastic and testing its pliability at small intervals to avoid overheating.
Once the plastic is ready, you can begin to smooth out the mould. Use the heat gun to gently apply heat to the areas of the mould that need smoothing. The heat will soften the plastic, allowing you to gently press or shape it with your hands or a tool. Take your time and work slowly, as the plastic will start to harden as it cools.
It's important to note that working with plastic and heat guns can be dangerous, so always take the necessary precautions. Wear protective gear, including heat-resistant gloves and eye protection, and work in a well-ventilated area to avoid inhaling any fumes. Additionally, keep a bucket of water or a fire extinguisher nearby in case of any accidents or fires.
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Prime and paint the fender flares
Before applying primer and paint to your plastic fender flares, it is essential to prepare them. Fender flares may still be coated in a thin layer of mould release from manufacturing, so start by cleaning them with a suitable cleaner, such as dish soap and water. Next, scuff the surface with 220 or 320-grit sandpaper to ensure proper adhesion. When sanding, cover every surface to be painted, transforming the semi-gloss sheen of the factory flares to a uniform, matte finish. With your flares fully sanded, wash them again with the dish soap and water solution. Once dry, wipe the flares with a clean microfiber cloth and your solvent of choice to remove oil and contaminants.
With your fender flares thoroughly cleaned and prepared, it's time to apply an adhesion promoter, being sure to follow the manufacturer's instructions. With the adhesion promoter dry, apply 2-3 coats of primer. Once the primer is dry, it's time to sand again. Sand the primer smooth, then clean the flares once more with dish soap and water, using a clean, lint-free cloth.
Now, you can apply a base coat of paint. Shake the base coat thoroughly before use, then apply a light first coat, followed by 2-3 medium coats. The result should be even and provide full coverage. If you're using a single-stage process, apply a final wet coat, and you're finished! If you're using a dual-stage process, once the base coat is dry (approximately 30 minutes), add a clear coat. Shake the can thoroughly, then apply one light coat, followed by 1-2 medium coats. This high-gloss paint will add depth and lustre to the flares, matching your vehicle's factory finish.
If you're looking for a more durable finish, consider using an etch primer designed for plastic before applying your paint coats. This will help the paint adhere better to the plastic surface and result in a longer-lasting paint job.
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Frequently asked questions
The first step is to glue the flares to the body of the car using a 3M panel body adhesive.
After gluing the flares, you should sand the area and apply a flexible body filler, which will help the regular body filler adhere to the plastic and prevent cracking.
The final step is to sand the body filler and prime and paint the car.
