New Body Panels From Scratch

General discussion about our beloved Tercel 4WD cars
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Kozuto_98
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My tercel:: 1987 SR5 Wagon
Location: Nova Scotia, Canada

New Body Panels From Scratch

Post by Kozuto_98 »

I've had some ideas floating around in my head about creating some new body panels from scratch using fiberglass.
My main focus would be making fenders and quarter panels as the fenders for these are hard to come across and tend to fetch high prices.

I'd start first by making fenders as that seems to be the hardest to find in good shape in my area. I have some practice making molds for
resin filling as I created a couple one off pieces for my 9th gen Corolla in the past. This also opens up the opportunity to make carbon pieces for these
Tercels.

Most of what I'll use will be coming from fiberglass supply, I've used product from them in the past and got really good results.
http://www.fiberglasssupply.com/default.html

I'll need to find a better driver side fender to make a mold off of because mine needed to be cut in a lot of places due to rust. My passenger side
fender will make a good mold as it's still all in great shape.

Thoughts as always are appreciated!
1987 Tercel Wagon SR5 4WD
1998 Honda Accord Coupe V6 J35 swap
1997 Acura CL (Sold for 4A-GE money)
RIP 2016 Civic (wrist pin recall)
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Petros
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My tercel:: '84 Tercel4wd w/extensive mods
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Re: New Body Panels From Scratch

Post by Petros »

I thought about this too for some time. I have done a little fiberglass work, thought if I used my own fenders to pull a mold I would have them if anyone wanted one. I could not figure what a good price would be, and that ultimately stopped me. since I do not need them myself, was it really worth all the effort?

what do you think you would sell them for. I would not mind buying some just to save some weight. what do you think about enlarging the flair a bit to accommodate larger tires too?

also have an idea to replace that massive front bumper with a lighter one out of fiberglass, with perhaps some updating of the appearance, more streamlined appearance. that I might consider a one off just because I want to get rid of that darn North American front bumper. I would glue foam blocks where the bumper goes and just keep caring away at it until I get something I like, and than fiber glass it. than it can be used to make a mold, if someone wants one.
'87 Tercel 4wd SR5 (current engine swap project)
'84 Tercel 4wd (daily driver, with on going mods)
'92 Mazda MPV 4wd (wife's daily driver)
'85 Tercel 4wd DLX auto(daughter's daily driver)
'01 Honda Civic (other daughter's daily driver)
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Kozuto_98
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Joined: Fri Jun 26, 2020 3:45 pm
My tercel:: 1987 SR5 Wagon
Location: Nova Scotia, Canada

Re: New Body Panels From Scratch

Post by Kozuto_98 »

I'd probably go sub $100 CAD for a fender. the fiber and resin is pretty cheap once the molds are made so they can pay themselves off pretty quick.
Extended flares for both front and back would really help give the Tercel a tougher look so I could look into making something akin to custom
fenders, and maybe even ones with proper snorkel exits.

If I can get my hands on them, I'd love to try and blend the styles of the stock USDM bumpers with the JDM Trueno bumpers.

I can understand stopping with making some, kinda seems like a lot of work for just one car. The effort can be worth in for helping preserve
these cars, plus there's the added benefit that fiberglass doesn't rust.
1987 Tercel Wagon SR5 4WD
1998 Honda Accord Coupe V6 J35 swap
1997 Acura CL (Sold for 4A-GE money)
RIP 2016 Civic (wrist pin recall)
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Kozuto_98
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Posts: 229
Joined: Fri Jun 26, 2020 3:45 pm
My tercel:: 1987 SR5 Wagon
Location: Nova Scotia, Canada

Re: New Body Panels From Scratch

Post by Kozuto_98 »

Forgot to mention, whenever I get around to making molds for quarter panels I'll have to decide on mounting points since you can't exactly weld
fiberglass. I'm sure I'll figure something out in due time.
1987 Tercel Wagon SR5 4WD
1998 Honda Accord Coupe V6 J35 swap
1997 Acura CL (Sold for 4A-GE money)
RIP 2016 Civic (wrist pin recall)
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LowBuckCanuck
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My tercel:: 1986 DLX 4wd Wagon "Jenny"

Re: New Body Panels From Scratch

Post by LowBuckCanuck »

I've thought long and hard about this, I even have a spare fender for if I decide to try.

You should make the molds and sell the fenders so I don't have to! ;)
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Kozuto_98
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My tercel:: 1987 SR5 Wagon
Location: Nova Scotia, Canada

Re: New Body Panels From Scratch

Post by Kozuto_98 »

LowBuckCanuck wrote: Wed Mar 17, 2021 11:38 pm I've thought long and hard about this, I even have a spare fender for if I decide to try.

You should make the molds and sell the fenders so I don't have to! ;)
:lol: Yeah, making the molds is the hard part. Takes a lot of time and patience to get it right.
1987 Tercel Wagon SR5 4WD
1998 Honda Accord Coupe V6 J35 swap
1997 Acura CL (Sold for 4A-GE money)
RIP 2016 Civic (wrist pin recall)
xirdneh
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My tercel:: 87 tercel 4x4 wagon w/reringed engine, 83 tercel 4x4 wagon w/salvaged engine and 4.1 Diff's
Location: seabeck, washington, USA

Re: New Body Panels From Scratch

Post by xirdneh »

What about getting one of those things that curve and shape sheet metal . I forgot what they are called “something “ wheel. Maybe English wheel?
Would take some practice
Love those Tercell 4x4 wagons but they sure suffer from road noise.
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Petros
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Re: New Body Panels From Scratch

Post by Petros »

yes, it is an "English Wheel". I have used one. it is a very slow way to shape metal into compound curved shapes. Aluminum is the best metal to use because it is easy to work, but making a whole fender seems to be a rather impossible task. way easier to find a good fender (or carefully fill and patch a not so perfect one), and use it as a plug to make a mold.

when I worked at the Nissan racing division we had most of the body panels made of fiberglass, and even "fake" bumpers but with a flair skirt, and added very large wheel flairs to the front fenders to fit big racing tires and wheels. they would build up the metal fenders with the desired flairs made of foam blocks and bondo and carve it to the desired smooth shape, and used that as the mold plug.

like this

Image
'87 Tercel 4wd SR5 (current engine swap project)
'84 Tercel 4wd (daily driver, with on going mods)
'92 Mazda MPV 4wd (wife's daily driver)
'85 Tercel 4wd DLX auto(daughter's daily driver)
'01 Honda Civic (other daughter's daily driver)
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Kozuto_98
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Posts: 229
Joined: Fri Jun 26, 2020 3:45 pm
My tercel:: 1987 SR5 Wagon
Location: Nova Scotia, Canada

Re: New Body Panels From Scratch

Post by Kozuto_98 »

I've never personally worked with an english wheel, but it's something I could certainly try in the future.
Aluminum fenders would be cool to see, and the material would make a good base for custom panels as it's pretty tough and lighter, but the vast
majority of my body work experience is from working with 20 gauge sheet steel.

If I had a welding setup to support it, I'd like to try making a semi-custom fender style with aluminum, but I sadly lack the funds and power hookups for that as of right now.

I never really considered using and carving foam to be used as a plug, that's something I'll for sure be trying out!
1987 Tercel Wagon SR5 4WD
1998 Honda Accord Coupe V6 J35 swap
1997 Acura CL (Sold for 4A-GE money)
RIP 2016 Civic (wrist pin recall)
xirdneh
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Posts: 2121
Joined: Thu Aug 04, 2005 11:38 am
My tercel:: 87 tercel 4x4 wagon w/reringed engine, 83 tercel 4x4 wagon w/salvaged engine and 4.1 Diff's
Location: seabeck, washington, USA

Re: New Body Panels From Scratch

Post by xirdneh »

I have seen pictures of entire car body done mostly with English wheel. Pretty skillful stuff
Love those Tercell 4x4 wagons but they sure suffer from road noise.
xirdneh
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Posts: 2121
Joined: Thu Aug 04, 2005 11:38 am
My tercel:: 87 tercel 4x4 wagon w/reringed engine, 83 tercel 4x4 wagon w/salvaged engine and 4.1 Diff's
Location: seabeck, washington, USA

Re: New Body Panels From Scratch

Post by xirdneh »

Love those Tercell 4x4 wagons but they sure suffer from road noise.
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Kozuto_98
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Joined: Fri Jun 26, 2020 3:45 pm
My tercel:: 1987 SR5 Wagon
Location: Nova Scotia, Canada

Re: New Body Panels From Scratch

Post by Kozuto_98 »

I'll have to check around the local shops here for one, if I can get and english wheel for a decent price I'll give it a whirl.
Using one of these would defiantly make easier work of doing the fender wheel arches and some other bits.
1987 Tercel Wagon SR5 4WD
1998 Honda Accord Coupe V6 J35 swap
1997 Acura CL (Sold for 4A-GE money)
RIP 2016 Civic (wrist pin recall)
User avatar
Petros
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Joined: Sun Jan 28, 2007 6:31 pm
My tercel:: '84 Tercel4wd w/extensive mods
Location: Arlington WA USA

Re: New Body Panels From Scratch

Post by Petros »

harpor freight has the best price, they can be quite costly for a professional tool. but I do not see the need for one on making car panels, fiberglass would be lighter and easier. perhaps for making aluminum skid plates, but that is a costly tool for just making those.

https://www.harborfreight.com/english-w ... 822f11dbee
'87 Tercel 4wd SR5 (current engine swap project)
'84 Tercel 4wd (daily driver, with on going mods)
'92 Mazda MPV 4wd (wife's daily driver)
'85 Tercel 4wd DLX auto(daughter's daily driver)
'01 Honda Civic (other daughter's daily driver)
User avatar
Kozuto_98
Top Notch Member
Posts: 229
Joined: Fri Jun 26, 2020 3:45 pm
My tercel:: 1987 SR5 Wagon
Location: Nova Scotia, Canada

Re: New Body Panels From Scratch

Post by Kozuto_98 »

Certainly cheaper than what Princess Auto offers. I think they're the Canadian Harbor Freight.
https://www.princessauto.com/en/english ... 0008536823
If I can buy just the wheels with the adjustment stuff I'll try making one from some box steel if I feel I need one.

Agreed on the fiberglass for being lighter and easier.
1987 Tercel Wagon SR5 4WD
1998 Honda Accord Coupe V6 J35 swap
1997 Acura CL (Sold for 4A-GE money)
RIP 2016 Civic (wrist pin recall)
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