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Old 04-16-2018, 03:38 PM   #151
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This morning I did the final sanding of the high build primer and then shot the JL-JK grille master with 2k clear coat for a smooth gloss finish to make the mold from. Normally you'd shoot a base color coat over the high build and before the clear but since this is a mold master and since there's no need for it to be a particular color I skipped the color step and shot the clear right over the high build primer.











I'll let the clear cure for a day and then I'll prep the master for molding with wax and PVA mold release. I'll do the fiberglass work to make the mold on Wednesday.

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Old 04-16-2018, 03:40 PM   #152
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A few more.





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Old 04-16-2018, 04:56 PM   #153
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Wow.

Hats off to you for the creativity and ingenuity.

I'd buy one.
Couldn't agree with you more. I can't wait to see the final project, this is why I love coming to these forums!
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Old 04-17-2018, 06:17 AM   #154
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A few more.





This may be a dumb question, but why can you not just paint that and put it on your JK? Do you like to make the mold so you can make adjustments and make multiple? Or does the mold give you something to pass on if a manufacturer wants to replicate and sell it? Or is there something about that grille as-is that makes it unfit to be used on the vehicle (besides the obvious unopened slots/headlights).

Thanks!
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Old 04-17-2018, 06:48 AM   #155
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This may be a dumb question, but why can you not just paint that and put it on your JK? Do you like to make the mold so you can make adjustments and make multiple? Or does the mold give you something to pass on if a manufacturer wants to replicate and sell it? Or is there something about that grille as-is that makes it unfit to be used on the vehicle (besides the obvious unopened slots/headlights).

Thanks!
It's a good question. While I could open up the slots/headlight buckets and install this one on the Jeep, it wouldn't last. Parts of it are wood, parts of it are sculpted with body filler that's thick enough that it would crack over time, and parts of it are bonded to the original factory plastic grille underneath and that bond won't last. A mold master like this only has to last long enough to make the mold so construction methods that wouldn't last on the vehicle can be used. Once the mold is made, this mold master can be tossed. I probably won't toss this one after I make the mold from it though , this one should hold up well enough to make a second mold from it so if a company decides to manaufacture these they can use this master to make their production mold, or, I could modify this one to make a different variant of the grille - for example a version with turn signal buckets to fit the stock turn signals.

And besides all that, a great reason to make a mold is that I can use that mold to make many of these grilles, so my work to create this master can result in a lot more than just a single part being made. Without a mold, how would I make, say, a barn door for my Jeep and another one for a friend (bottom photos) ...

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Old 04-17-2018, 03:52 PM   #156
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Very Nice work, jscherb.
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Old 04-17-2018, 07:29 PM   #157
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Very Nice work, jscherb.
Thank you very much.


Project update: I've prepped the master with wax and PVA mold release (that's why it's a bit green in the photo below) so it's now ready to do the fiberglass work to make the mold tomorrow.

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Old 04-17-2018, 07:42 PM   #158
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Very nice. That is the by far the best looking grille I've seen for the JK.
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Old 04-18-2018, 06:47 AM   #159
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[QUOTE=jscherb;33247058]
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Originally Posted by spiderx View Post
Very Nice work, jscherb.
Thank you very much.


Project update: I've prepped the master with wax and PVA mold release (that's why it's a bit green in the photo below) so it's now ready to do the fiberglass work to make the mold tomorrow.

[/QUOTE

Great work brother it looks so good, i think you should make a few for members that have been here in this forum the whole time with you. We deserve it lol.
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Old 04-18-2018, 07:19 AM   #160
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This is going to be awesome. I can tell by the attention to detail that you put into this, it's going to be quality.
Also, it seems like you are having fun figuring it out. Great job.
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Old 04-18-2018, 09:08 AM   #161
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This is going to be awesome. I can tell by the attention to detail that you put into this, it's going to be quality.
Also, it seems like you are having fun figuring it out. Great job.
Thank you. There's really no point in doing this project unless the final result is of factory quality. I think anything less would make the whole Jeep look bad.

I mostly enjoy the beginning and the end of these projects - I enjoy the design process at the beginning and having the end result on my Jeep. In the middle I enjoy the fabrication work well enough, but I very much dislike the fiberglass work. (BTW if I don't make any more than one or two for my own use it'll be because making more would mean more fiberglass work for me).

Project update: Step 2 in making a mold (Step 1 was the wax and mold release) is shooting gelcoat on the surface of the mold master - I shot orange tooling gelcoat on the mold master this morning. When that cures to the appropriate point I'll do the fiberglass layup.

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Old 04-18-2018, 10:24 AM   #162
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Amazing work , following
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Old 04-18-2018, 03:21 PM   #163
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I made the mold for the grille today. It needs to cure overnight so tomorrow morning I'll pop the mold off the master and we'll see what the mold looks like.

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Old 04-19-2018, 07:52 AM   #164
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This morning I pulled the mold off the master.



The mold master could be used again to make another mold - if the grille were to go into production I'd turn over the master to the company that would be making/marketing them so they could make their production mold from the master.

After trimming and washing off the mold release, the mold is ready use. The mold turned out very nicely - it will make very nice quality grilles.







I'll make the first grille in the mold tomorrow.
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Old 04-19-2018, 10:24 AM   #165
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@jscherb your inventiveness constantly impresses me. Thanks for sharing the process of putting something like this together.
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Old 04-19-2018, 10:45 AM   #166
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@jscherb Awe Inspiring! Nothing else to say... (And that is unusual for me!)
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Old 04-19-2018, 12:21 PM   #167
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Originally Posted by jscherb View Post
This morning I pulled the mold off the master.



The mold master could be used again to make another mold - if the grille were to go into production I'd turn over the master to the company that would be making/marketing them so they could make their production mold from the master.

After trimming and washing off the mold release, the mold is ready use. The mold turned out very nicely - it will make very nice quality grilles.







I'll make the first grille in the mold tomorrow.
Wow brother would you please make one for me i will pay you good money and shipping via paypal please . Email me at [email protected]
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Old 04-19-2018, 12:25 PM   #168
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Originally Posted by Lessmlj View Post
Quote:
Originally Posted by jscherb View Post
This morning I pulled the mold off the master.



The mold master could be used again to make another mold - if the grille were to go into production I'd turn over the master to the company that would be making/marketing them so they could make their production mold from the master.

After trimming and washing off the mold release, the mold is ready use. The mold turned out very nicely - it will make very nice quality grilles.







I'll make the first grille in the mold tomorrow.
Wow brother would you please make one for me i will pay you good money and shipping via paypal please . Email me at [email protected]

I also have a friend interested in buying the mold he owns skullcrusheroffroad and he wants to know what you want for the mold, do you have contact info?
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Old 04-19-2018, 02:53 PM   #169
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@jscherb Awe Inspiring! Nothing else to say... (And that is unusual for me!)
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@jscherb your inventiveness constantly impresses me. Thanks for sharing the process of putting something like this together.
Thank you very much.

Glad to share, hopefully people will get ideas for their own projects from what I post.
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Old 04-19-2018, 03:01 PM   #170
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Wow brother would you please make one for me i will pay you good money and shipping via paypal please . Email me at [email protected]
Thanks for your interest. After I get the first one molded, finished and installed on my Jeep I'll decide if I'm going to make a few more for forum friends.

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I also have a friend interested in buying the mold he owns skullcrusheroffroad and he wants to know what you want for the mold, do you have contact info?
I have no plans to sell the mold, but I am willing to let the mold master go to a company/person interested in producing/marketing the grille. The mold master can be used to make a production mold to whatever process standards the company/person requires. I can be reached via PM on JeepForum, or via email on the Expedition Portal, sorry but I don't use PMs on this forum.
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Old 04-20-2018, 06:02 AM   #171
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@jscherb if you ever make a version of the grill that accepts marker lights sign me up for the first one that pops out of the mold! Your work is phenomenal and it would be very cool to have one of your parts on my JK.
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Old 04-20-2018, 06:27 AM   #172
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@jscherb if you ever make a version of the grill that accepts marker lights sign me up for the first one that pops out of the mold! Your work is phenomenal and it would be very cool to have one of your parts on my JK.
Factory JK marker lights can be installed in this grille using the same steps that are used to install JK marker lights in TJ grilles - it's very commonly done on TJ's with flat fenders. It's easy to do and there are many writeups on it out there.



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Old 04-20-2018, 06:30 AM   #173
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I just get so excited to check this thread everyday! lol
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Old 04-20-2018, 09:37 AM   #174
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Project update: This morning I prepped the mold and shot it with white gelcoat. I also have black gelcoat on hand and was considering molding the first grille in black but since I'm going to paint this one body color to match my Jeep I went with white. Around lunchtime I'll do the fiberglass layup.

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Old 04-20-2018, 03:40 PM   #175
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The fiberglass layup work is done on the first grille; JL-JK grille #1 will come out of the mold tomorrow morning after curing overnight.

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Old 04-20-2018, 03:48 PM   #176
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Nice work, this is fascinating to watch. Thanks for sharing it.
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Old 04-20-2018, 05:11 PM   #177
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Man! I wish I was half as crafty as you. The things you come out with and create are great, and fun to watch the progression. Of course I could be added to the list of potential buyers whether you or another company buys this from you. It's only a matter of time til these are made and you already did the hard work for them. I'll be here watching for more updates!

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I made the mold for the grille today. It needs to cure overnight so tomorrow morning I'll pop the mold off the master and we'll see what the mold looks like.

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Old 04-20-2018, 06:08 PM   #178
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Factory JK marker lights can be installed in this grille using the same steps that are used to install JK marker lights in TJ grilles - it's very commonly done on TJ's with flat fenders. It's easy to do and there are many writeups on it out there.





Oh, you are just teasing right? All the work you have put into that mold and making every little adjustment to make it as accurate as it is and you just want me to drill holes in it for lights? No way.. Did you feel bad after hitting post on that reply? Hahaha..
See the problem @jscherb is we all know the amazing work that your capable of here. If i wait long enough you will mold in the marker lights as you know they should be.... I can wait..... Hurry up!!
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Old 04-20-2018, 07:52 PM   #179
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...If i wait long enough you will mold in the marker lights as you know they should be.... I can wait..... Hurry up!!
No, I won't, sorry. I have other projects I want to move on to, I have no plans to spend time doing another version of this grille.
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Old 04-20-2018, 08:10 PM   #180
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No, I won't, sorry. I have other projects I want to move on to, I have no plans to spend time doing another version of this grille.
Oh well. Great work anyway. I would go so far to say "Almost Perfect!" Haha.

I can build the world out of metal but your fiberglass skills amaze me! Some day I will have to start working with it.

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