Putting on my bragging hat...

[GassMann]

Hey all,

My 1966 Charger front fender chrome has some challenges. The LH side was damaged. The RH side was gone. I just finished painting it and could not go back, cut, weld and close all the chrome.

So I made a model of what I think are original shapes.


And cast new ones in Aluminum.

There's a small porosity spot on one side that I will most likely recast. The one on the left is fresh-cast. The center is the original that I have, the one on the right is ground, sanded and polished.

I think it look better than the one I have and FAR better than the one I am missing. Next, I need to mark holes, drill/tap and mount studs to I can mount them to the fenders.

I have the core models. If anyone is interested, let me know and I will cast some more.

Cheers all...

 

[Black_Sheep]

That’s cool…

 

[junior340]

Bravo!!

 

[Don Frelier]

Wow!
Amazing

 

[70bigblockdodge]

Nice job

 

[sam dupont]

Lost wax method?

 

[GassMann]

Lost wax method?

No... used a profiler tool to capture the initial curve. Laid that out on 18"x 2"x 3/4" VG pine. Cut it on my bandsaw to prelim-shape it. Then belt sanded it to tighten the profile. I laid down tape on the fender, the covered the bottom of the model with body filler and set it down on the fender so it picked up the exact profile and curve. From there, I hand shaped and sanded them to size, keeping the profile closely matching the original. Then covered each with glazing putty topcoat. Finished with fine sanding and gloss paint.

After a few test fits and fine tuning by sliding the male end of the mold into the original female side of the long fender molding, I use green sand-casting method. It took a few tests pours to get it to turn out right. After pulling of the dross and making sure the aluminum was hot enough, I poured.

After cooling and cutting off the sprue's, I belt-sanded to a rough finish then hand sanded to a finer finish. A buff and polish later and presto... I will post a pic tomorrow with it mounted.

 

[PlymCrazy]

Hmmm, make your own? That’s ingenuity and determination. Great way to add to your car’s story imo.

 

[GassMann]

Here's how it turned out. I think I will make another one as this has some porosity near the tip. But overall, I think it will do the trick. Link to a short video below.
20230715_183607.mp4

 

[WileE]

nice work, I admire craftsmanship