Composite Body Panels

[SuspiciousPizza]

I've been talking to a coworker who does composite work on the side. Right now he only focuses of making carbon fiber parts for KTM super motos.

I've had the idea for a few weeks to start manufacture of NLA body panels for these old Subarus. I talked to him about this and he doesn't have any objections to taking on the project but he doesn't know if there's a market for these parts. Making the molds takes significant investment of both time and money.

Would anyone be interested in composite body panels?

I'm thinking just fiberglass (to keep the cost down) but face layers of carbon or kevlar would be possible. Or even panels made entirely of carbon or kevlar would be possible. No sanding, no paint. They'd ship as bare parts to he finished by the buyer (or just throw them on without sanding or paint).

If anything we'd start with 3rd Gen front fenders and hoods and we could move from there if there's enough demand.

Just putting feelers out there if this would be worth our time. No ideas on a price at this time.

:]

 

[bushytails]

I think there's about a whole dozen of us still working on old gen subarus...

[moosens]

Not likely worth the mold making effort. 
 

There are fiberglass front fenders out there for gen one that show up once in a while. I might even still have one. 

There were two shops that did those or at least two different results. Some have a wicked nasty orange peel texture and others don’t. Mine is the smooth finish type. Some seems to come from Canada and not sure about the others. One seller in the Pittsburgh area had a small amount of them a few years back. That guy seemed to fade away but those were the lower quality anyways.

 

Back to contemporary composite panel construction, I also work with the stuff with autoclaves and molds and all that fun stuff. But I’m not about to start mold making. Had thought about just vacuum bagging the panel with a homemade caul plate. But I don’t have time and space. And I do that stuff at work for aircraft. 
 

Also in the “wuz gonna” file is the front air damn from Kamei that I had that I think Galen H has now. 

[el_freddo]

The other issue with these ideas and looking for numbers of those that put their hand up to buy. Subaru owners are typically tight on stuff like this - yes ppl in a way if you like - but once it comes to the commitment to buy most of them will scamper! 

This happens time and time again. Someone needs to pony up without any expectation of others buying to cover costs. This bit sucks. Then you just wait & hope that the units sell. Much like the remanufactured tailgates here in Oz. Someone made them with ppl aware of them being made. From my understanding they sold several batches, I don’t know how many were in a batch. 

These were very well made and I want one, but other priorities plus my brumby isn’t the best looking one getting around but it’s complete and can be dailyed if I want. 

I do hope you work out a way to make it happen if this is what you want @SuspiciousPizza!

[moosens]

Right, Benny picked up where I left off or didn’t quite declare too well. 
 

Demand.

 

And what Benny said about the community is 100% dead on. 
 

SP - we can surely appreciate your enthusiasm but you’ve got to realize there’s a few of us who’ve travelled the same path of thought. Only to see the light/darkness and turn back. 
 

The one good group purchase we did , we actually did a second successful purchase as well , was for the front windshield rubber gaskets for gen one. 
 

Been talk about lots of possible repro parts but no way is a manufacturer going to get involved given the vintage Subaru numbers. 
 

Back yard, basement, garage efforts are super great to see. And I’m still always scheming to try to work out some type of personal vacuum bagging, makeshift autoclave type of set up. 

[SuspiciousPizza]

If you were in the market for these parts what would you consider a fair price for the different panels?

Also I'm not excluding the possibility of 1st and 2nd gen body panels. 

Just throwing ideas out there.

 

[el_freddo]

Sorry to say mate -  

That question is where it always starts. I’m not in the market for composite panels so I have no idea. 

And again, what someone is willing to pay theoretically and what they choose to do about a purchase is another thing. 

Many ppl get a better kick out of researching holiday ‘what ifs’ than they do attending the actual holiday experience. Same goes for the prospect of cool reproduction parts. 

Someone might bite the bullet and just do it, it needs to be a special someone that does it without seeking full reimbursement or good profits - that’s not to say it can’t happen though, just don’t peg your expectations that it will go that way.  

I’m not trying to, or wanting to dissuade you from pursuing this idea; I am being the realist for you from what I’ve seen in the past with Subaru aftermarket small batch items. 

All the best!

Edited 11 hours ago by el_freddo

[moosens]

Caused me to chuckle somewhat , yes that’s the other issue among our beloved community. Thin wallets. But hey I’m among that group.

 

Best car for thrifty types with even minor skills to be able to maximize roadworthiness.

 

The fiberglass fender I bought on eBay many years ago like maybe the late 90s and pretty sure I paid $15 and fairly cheap shipping. 
 

Nothing is going to really make your old Subaru driving experience any better beyond dropping in an EJ22 and appropriate drive train. 
 

Kind of tricky with these old relics. Honestly I think like you do SP , somewhat. But no way beyond just personal use. 
 

There’s at least one guy in the Ducati forums who vacuum bags his own ideas for things like foot pegs and clutch cover , instrument mounts, etc. 
 

Yup, I’ve got my ideas too. For my 73 Coupe I’m thinking it’s an easy effort to make my window trim in carbon fiber. And more. But no sense spouting ideas I don’t really have the shop and equipment for. 
 

But like I said before it’s nice to see personal efforts. Like that guy on the Ducati forums I mentioned. Enjoy !