Epoxy/Fiberglass Tutorial | VW Microbus Electric Go-Kart Shell
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- čas přidán 30. 05. 2019
- In this video we create a cool VW Minibus Go Kart Shell using low cost EPS foam board and BJB's laminating epoxy with fiberglass cloth. Starting with a donor go kart frame, we show the materials and techniques used to make the fun-sized VW Electric Microbus replica.
(For power details- Motor/Battery, see below)
Here is the list of products used in the video:
TC-1604 Laminating Epoxy: bjbmaterials.com/epoxy/lamina...
TC-4206 Epoxy Adhesive Paste: bjbmaterials.com/tc-4206-a-b/
SEM High Fill Primer: bjbmaterials.com/coatings/sem...
Armor Bond Fast Curing Polyurethane Adhesive: bjbmaterials.com/ap-3220-a-b/
BJB's Website: bjbenterprises.com/
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*Power and Frame Details*
The frame is originally from a Honda Minimoto Go-Kart. It was a 500 watt, 36V power unit. The original plastic body parts were all removed and a new seat location for larger riders was constructed. The new motor is 1800 watt brushless using a 32 amp speed control. Battery is 48V, 10 AH capacity e-bike pack. Top speed estimated at 25mph/40kph.
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#bjbenterprises #bjbmaterials #moldmaking #moldingandcasting #gokart #epoxy #fiberglass #carbonfiber #automotive #volkswagon #vwelectricbus #microbus #electriccar #tesla #teambjb - Jak na to + styl
This is such an awesome job, Troy! Great project and great how-to video! This is one of the things I love about your CZcams channel. I’ve been doing fiberglass work, custom painting/body work, and mold making for about 25 years, but I still always learn some new “tips and tricks” from your videos. Keep ‘em coming, guys an’ gals!
Hi Robert, thank you for the feedback and compliment. Glad you enjoyed the video. We also learn so much from our talented customer base so it certainly goes both ways. Our little bus is making everyone who sees it smile so mission accomplished!
This is what I’ve been looking for
This is awesome
What a great job! Still working on the parts using the shore 55 D urethane you guys helped with. Next part happens to be a composite one. You will be hearing from me soon.😁
Awesome to hear, hope to see your results soon!
Looks great! had me headed to craigslist for a cart frame :)
Yes, it's a delightful slippery slope! Also more fun than a real one, too.
The best way to reach us for product questions is our email: info@bjbenterprises.com
This is awesome i plan to build a 69 daytona one day and this will come very handy, thank you👍
How much fiber glass cloth did you end up using on this project, I’m doing a similar project and feel like I’m over estimating how much I need. Thanks!
I wish u would have mad a lamborghini or cadillac cts v coupe but none the less great job giving me ideas
Can you also use this for a 75mph petrol go cart?
I want to build a jaguar e type go cart it Will be pretty big lenght Will be 302cm
Width 111cm
Height 82cm
I see this more than 20 times
Please make mini wv beetle
In the future, would you guys ever do one of these builds for a customer? I would love to have one of these done that looks like a Aston Martin DB5 and seeing the amount of very detailed work you guys have done with this bus, it would be amazing to have this done to a dream build of mine
Unfortunately no. We are quite busy with producing the raw materials for applications like this and our customer base is the place where finished parts are made.
Love it, looking to find a shell
Thank you! It brings a smile to everyone that sees it.
Awesome job! Are there any available for purchase? I would love to have one! I have a 70 Camper and would love to tow this behind me to scoot around the campgrounds!
The bus you see is the one and only. We did not make molds to create more. It's made some appearances at a local parade and car shows and it always gets tons of smiles.
Wander how hard it would be to make a 65' Ford falcon body like this? Would love to do it for the kids to match my car 😁
That would be super cool. We have many customers that make a variety of cool parts so if you take the challenge we've got the materials. Check out our BMW Isetta lens video for more automotive mold making tutorials: czcams.com/video/WME8R2-Ot8E/video.html
How does the epoxy compare to normal fiberglass resin i worked in a shop? Where to get fiberglass cloth?
thetermite72 great question. The big difference is that polyester resin will melt the foam while Epoxy won’t. Epoxy is also stronger by weight and is easy to paint and bond to. Fiberglass cloth can be found by many sources including our Distributor Revchem along with many online sources. We used 6 ounce plain weave on the bus.
Is it possible to make a tutorial making of the van???? Awesome!!!!!
Can you clarify? This is a video of making the bus shell. Are you referring to the rest of the go-kart?
@@bjbenterprises yes. The cutting part is what I was referring to.
@@badfamemedia we don't have a specific video or post online showing the foam cutting process, but we could do some "behind the scenes" posts if there is interest. Most of the foam carving and assembly was captured on still pictures with a few GoPro time lapse shots. Follow us on Instagram or Facebook and keep an eye out for it.
How hard is the material when it's ready (the shell)? Is it as hard as plastic?
Yes, it is durable fiberglass and epoxy so it is actually tougher than just plastic. The hardness and stiffness of the skin depends on how many layers of fiberglass you apply.
That thing is simply beautiful. Did you remove the foam after you were done, or leave it? What are your thoughts on removing the foam, and using a chop gun on the inside? Do you feel the body is strong enough as is if you bump into something, or God forbid tip over?
Hi Kirk, thanks and good questions. We leave the foam in there for a couple of reasons. First, it strengthens the fiberglass skin tremendously without adding a lot weight. You can achieve the same stiffness and overall strength with less fiberglass compared to a molded skin with no core. If we had closed out the whole interior with a layer or two of fiberglass and epoxy, it would add only a small amount of weight but strength and stiffness would increase dramatically. We did a few areas of reinforcement on the inside for mounts, but that was really it. In regard to chop gunning the inside, that would imply using polyester resin and that would not work as the polyester eats white beaded foam. That's why we use epoxy resin. Overall durability of this shell is fairly good and will take some bumps or minor hits, but it's not built to withstand roll overs. This cart is so bottom heavy and wide, a roll over is unlikely.
@@bjbenterprises thank you for the rapid reply!!
This is the most baller thing you should do this for an AE86
Thanks, and yes, you can have fun making lots of car designs with the process. Even an AE86... with 80's pop up headlights.
I notice the interior is black after you're done. Did you just paint it or did it also get some sort of reinforcement?
We simply painted it to improve the look. There were strategic areas inside where we did add reinforcements due to mounting fixtures and such. However, we did not fiberglass the whole interior like the outer shell. Simply not needed.
Do yoi guys host any work shops? Would love to attend one
Hi there, we don't have anything in the works given the current situation with COVID. If you have a project and need help, our tech team is well versed in providing support and recommendations on mold making and casting. 714-734-8450 or info@bjbenterprises.com
I want to make a wide body scion FRS body for an electric frame, would that work? Oh, and great vid! I have been looking for help around enclosed go karts, but only find pre-made ones. Thank you!
Edit: are you supposed to take off the foam because you didn’t mention it in the video?
Hammy And Friends the foam is left to add extra support and rigidity. Although not necessary in this case, adding fiberglass to the inside would have made it even stronger making a true sandwich construction. Hope you are inspired by this video and try your own project. Let us know if you have material questions.
Do you keep the styrofoam on the the fiberglass or do you take off the rest
Typically you just leave the foam because it doesn't weight much and it also adds much more stiffness to the structure. If you add fiberglass to the inside surface (which we did in a few key areas) the strength increases drastically. Thanks for your question!
@@bjbenterprises I seen some with out the foam maybe it's to have the fiberglass feel to it
@@ddrusa It's likely because they built fiberglass shells from a mold and manufacture many parts at a time. This is a method to create a on-off fiberglass part vs making a mold. We could easily take a mold off of this shell and create more parts if the need and desire was there for it.
@@bjbenterprises Ah ok I get it now thank you
Someone needs to make a mercedes shell for a go kart because mario kart did it in games
I would love to get the dimensions for this project, I'm will be going in the Hejaz Shriners soon and I would like to build one of these for riding in the Shriners parade. Can you please help me with this project?
Are you looking for the rough dimensions of the shell only? That is fairly easy. The chassis and the rest is a little more involved since it was built off an existing electric Go Kart: Honda Minimoto.
The shell measurements are as follows: Length 140", width 30", height 27". The driver cutout area is 30" X 20".
how long did it take
The whole project or just the shell? The foam took a couple weeks of evenings and the glass work paint and body took a couple more weeks of part time work.
How much for the vw bus the fiberglass
Marko Gonzalez are you asking how much the fiberglass is or how much the bus cost to build?? Your question isn’t clear.
If only I could carve foam also. 🤣🤣
How much the vw bus go kart fiberglass
Marko Gonzalez are you asking how much the fiberglass is or how much the bus cost to build?? Your question isn’t clear.
Hey guys, I need some help :/
I'm trying to make almost the exact same thing but slightly scaled up. I want to be able to use the side doors to get in and out and have the top of the shell over my head. I would need to have some windows as a result. Currently I have a 6.5hp engine from an old lawnmower that I'm going to convert but I don't know if it will be enough to actually drive the weight of me and the Go-Kart frame + shell. I'm 6ft tall and around 150 pounds so if anyone has an estimate of how heavy the build would be then I could do the math and see if there's enough power. Hope everyone's having a good day!
That sounds like a cool project and certainly you can use this technique to quickly and effectively make a fiberglass shell. This is also a great way to make the pattern for producing fiberglass molds, too. SInce you are asking about power requirements and frame construction, you might be better off finding some sort of Go Kart Facebook group or online forum for this. There are some great, informative groups that specialize in these types of projects. Either way, there will be some R&D to make a custom, driving vehicle as you described and let us know if you need epoxy materials to laminate the composite fabrics. -BJB
@@bjbenterprises Thank you very much for the tips, I will be sure to reach out!
I know this video is 4 years old, but what was the cost of the project?
Hi there. It's difficult to put a cost on the whole project because most of the kart (excluding the body made in the video) came from used parts and pieces. Materials to make the body are likely around $400-$500 for TC-1604 epoxy, fiberglass fabric, SEM primer, body filler, sandpaper, paint, vinyl decals, 3D printed parts, and so on. The 1800 watt motor, speed control, and lithium 48v battery were found on Amazon (about $350). To build something like this from scratch, you are looking at $1000-$2000 depending on the fabrication skills you have and materials used to build such a car. Finding an old go kart frame and modifying like this helped save a lot of money and time.
I really liked the tutorial, but I'm wondering if you could take the mystery out of the audio situation? Because at times, especially when you speak, the audio is really rough.
Matej Porubovic thank you for the feedback. We had a wireless microphone issue and have since replaced it.
an im making a go cart truck
How / why didn't the epoxy eat away the Styrofoam? I thought that epoxy would melt the Styrofoam?
Hi Jim, great question. You are thinking of Polyester resin which will eat EPS foam. Epoxy resin does not contain the solvent styrene which is in high concentration in polyester resin.
@@bjbenterprises does all epoxy not come with the solvent or is it something that has to be mentioned or looked out for when buying some? I want to try this out.
@@luislopez-vx5zj epoxy is foam safe. What you are hearing about resin eating foam comes from the lack of understanding from newbies in composites that confuse the term "fiberglass resin" and don't know there are epoxy resins and polyester resins. Polyester resin is common in the DIY world because it is very simple and user friendly due to the way the catalyst is added in drops. Epoxies you typically weigh out on a scale and that scares some newbies for some reason. If you go to buy "fiberglass resin" at a hardware store or boat shop, you might not realize that it is actually polyester resin and that will eat the foam and sometimes people selling it don't even know the difference.
@@bjbenterprises thank you for the explanation. I tend to buy the “General Use” Resin and some gel coat they sell at the local supply store but have never actually looked into other applications. I’ll be checking to see if I can buy some epoxy resin locally if not I’ll be going online I’ll just make sure to get the ratio down needed for the correct measurements.
Little kid ask can I ride it. can you see anything?
Many kids have driven the Bus.
make it gas powered it is an like guaranty
That’s Tate McRae’s old intro
We have no idea what that means but we'll assume she has good taste then.
It was a green video btw
Gaming Squad we love the color green.
I meant great video sorry