How to make your own fiberglass bumper

[babybolt]

 "I'd like to dump the cast iron brake reservoir (hard to find a direct replacement) "

The mid-80's Ranger pickup had an aluminum master cylinder that looked very similar to the late 60's to early 70's Mustang unit, and the lines even exited the drivers side.  I don't know what the bore sizes were on the Ranger.  At the end of the 80's Ranger they switched to the type of master cylinder with the plastic reservoir.  If you order a replacement master cylinder for the Ranger now they would probably come with the plastic reservoir, but if you could look through old stock or hit a junkyard an aluminum unit might show up.

[Nightmist66]

We use this master cylinder for ours. Fits the Fairlane and even clears pentroof valve covers, steel and finned aluminum.
DORMAN M39568   
{#E6TZ2140B} 
 Manual brakes; Bore: 15/16 In.   Got it from Rockauto.com



Jay, I would also like to know how the chroming process works out for you and as always, excellent work!

[cjetmech]

This kinda stuff is why I think Jay is the ultimate gear head. The guy does EVERYTHING himself. 1000hp SOHC? No problem. Body work and paint? No problem. Wiring and programming electronics? No problem. Dyno Tune? No problem. Mig/Tig..Etc Etc Etc. But the best part is that you share all this knowledge with everybody. I really appreciate it. I sure am glad your an FE guy!! Got any pics of some of those r/c planes that you built?

[machoneman]

"I'd like to dump the cast iron brake reservoir (hard to find a direct replacement) "

The mid-80's Ranger pickup had an aluminum master cylinder that looked very similar to the late 60's to early 70's Mustang unit, and the lines even exited the drivers side.  I don't know what the bore sizes were on the Ranger.  At the end of the 80's Ranger they switched to the type of master cylinder with the plastic reservoir.  If you order a replacement master cylinder for the Ranger now they would probably come with the plastic reservoir, but if you could look through old stock or hit a junkyard an aluminum unit might show up.

Great and thanks! I will look into that.

[WConley]

Looks great Jay!  I can appreciate all of the thought that went into that process.  Look forward to seeing a finished bumper on the car 

[babybolt]

85 and older Ranger had the aluminum master cylinder that looks like the earlier Mustang units.  Rockauto sells new replacements made of aluminum with a 15/16" bore.  I think the castings on the original aluminum Ranger cylinders was a little different.  Some of the master cylinders sold at Rockauto for this application are iron castings so you have to read the fine print.

http://www.rockauto.com/en/moreinfo.php?pk=309668&cc=1137350&jsn=991

[cjshaker]

Next, he'll be going on the Atkins diet to lose another 30 lbs. Stay tuned...

[machoneman]

85 and older Ranger had the aluminum master cylinder that looks like the earlier Mustang units.  Rockauto sells new replacements made of aluminum with a 15/16" bore.  I think the castings on the original aluminum Ranger cylinders was a little different.  Some of the master cylinders sold at Rockauto for this application are iron castings so you have to read the fine print.

http://www.rockauto.com/en/moreinfo.php?pk=309668&cc=1137350&jsn=991

 Great! I'll look into this one as well. Thanks to all!

[Cyclone Joe]

Howdy Jay,
Nice work there sir!  Have you considered swapping out the fiberglass for kevlar?  Its half the density but about the same strength.  Since you have the molds, it might be worth it if you're trying to cut as much weight as you can.  Just be sure to purchase ceramic scissors...kevlar is tough stuff but those scissors cut through the stuff really easily.

Joe

[stubbie]

Don't know a lot about FE engines but I do about fiberglass. Jay instead of using Cabosil you could use fiberglass tissue. It will conform to your sharp curves and weigh less. If you have sharp corners get some fiberglass woven roving's that is sprayed in a chopper gun (fiberglass rope) and lay that into your sharp corners first then lay your glass matt over that. Less chance of air bubbles. Also fiberglass is like concrete it takes about 20+ days to cure correctly so leave your molds to cure for longer periods before removing them from any pattern. Nice work on your mold by the way.
Cheers

[jayb]

Thanks for the tip, I've never heard of fiberglass tissue.  I will have to look into that stuff...

[stubbie]

Yes it's about 1/2 an ounce and works great in tight spots.

[Royce]

I have a new aluminum master but lines come out the wrong side .. It needs a new home