I have done quite a bit of fibreglass work in my time and decided I would like to make some gage pods for my Nissan Stagea. The originals were made of anything I could use to make the shape I wanted, this is commonly referred to as a plug or pattern. A mold is then created from this pattern and parts are made from that mold. I will spare the readers that process and focus on how a produced part is finished.
When the parts are first pulled from the mold they are quite rough and raw as can be seen in the photograph below. The parts need to have the excess on the edges of the part filed or grinded off. Due to the shape of the part it is a 2 piece mold so a seam must be sanded back from the centre of the part as well, this may require some body filler to smooth out any discrepancies in below the gelcoat surface. Sanding the complete surface of the part with around 400 grit paper preps for paint. A holesaw with the appropriate size is used to make the opening for the gauges. It is also a good idea to trial fit the gauge in the pod and the pod on the vehicle throughout the process.
Raw gauge pods straight out of the mold.
Once the part has been cut back and smoothed out, we can clean the surface with wax and grease remover and when the part is dry we can apply the first coat of primer. Dust coat work best and reduce the chance of runs and fish eyes in the paint. Then the colour and clear coat can be applied to create the finished look.
Primer Coat
Colour and Clear Coat Down
A quick trial fit again making sure that the pods sit in the right spot and face the way you want is next. Measure many times and do the work once. Mark the pillar at the right spot and then remove the pillar, make holes in the pillar at the appropriate places to feed the wires through to the gauge. Urethane is used to keep the pod in place and then is left for 24hr for cure time or it can be fitted but taped up for 24hrs…. but you run the risk of the tape giving way.
Trial Fitting
The completed product is a nice fit and houses a boost gauge and a air fuel mixture meter. Wiring is done properly with solder and clips for easy removal if the pillar needs to come out for any reason. It definitely gives the cabin a cockpit feel when driving. Very happy with the outcome and have the molds if others need a gauge pod for their Stag, have made a few for other people.
Cockpit View
