Category Archives: Automotive

A Magnesium Crankcase Repair

By Rob Van Mullekom

I accidentally punched a hole in my motorcycle’s magnesium crankcase or ignition housing cover. A lot of the guys I work with also ride motorcycles, and in talking with them, I found out that it is not uncommon to punch a hole in the crankcase.  I work here at Gougeon Brothers, Inc. as Operations Supervisor in the Epoxy Department where we do production mixing, assembly, packaging, and quality control of WEST SYSTEM® Epoxy.

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Test blocks glued to the underside of the cover.

Plastic Engine Cover Repair

By Jeff Wright — Vice President of Technical Services

My wife’s 2000 Audi TT has a very sleek shape, and these smooth lines are carried under the hood with molded plastic engine covers that provide a very clean-looking engine. Unfortunately, when I was servicing a burned-out bulb, I attempted to remove the engine covers in the wrong sequence which caused a tab to snap off.   Continue reading

The repaired panel is back in place on the camper. A coat of Krylon Fusion™ textured, plastic- compatible paint completed the repair.

Camper Panel Repair

By Tom Pawlak — GBI Technical Advisor

Above: The repaired camper panel is back in place on the camper. A coat of Krylon Fusion® textured, plastic-compatible paint completed the camper repair.

Todd Lynch, one of our valued employees, brought in a damaged plastic panel from the back end of an 11-year-old pop-up camper and asked if it was worth fixing. It came from his hunting camper which had been rear-ended. He just wanted it to be functional. The impact had made cracks at nearly every screw hole for holding the panel in place, making it doubtful it would last another trip down the highway. Continue reading

Scale Ferrari

Building a Grandson’s Formula 1 Ferrari

By John White of Fife, Scotland

When the first grandson arrives, any grandfather knows he now has the chance to fulfill the dreams he had as a boy. A Formula 1 racing car would do for starters. A small model purchased for £4 was the starting point. The car will be ready for his third birthday so plenty of time (or so I thought). Continue reading

Shown upside down, the base of the trailer is a series of plywood torsion boxes, doubling as storage compartments. The depth of the boxes makes a very light weight, rigid structure.

Projects & Tips from the Shop of Jon Staudacher

by Brian Knight—GBI Technical Advisor

Above: Shown upside down, the base of Jon Staudacher’s trailer is a series of plywood torsion boxes, doubling as storage compartments. The depth of the boxes makes a very lightweight, rigid structure.

Over the years, we have featured some of Jon Staudacher’s more innovative projects and ideas. From his extreme house, to race boats, to aerobatic airplanes, to a gate at the end of his driveway, to something as simple as a paint roller brake, Jon has always sought the simplest method to build his projects. Jon’s latest project is no exception.

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racing dinghy

Readers’ Projects, Issue 18

Contender Class Single-Handed Racing Dinghy

This Contender class single-handed racing dinghy was built in Italy by Bonezzi in 1994. Joachim Rosler of New Canaan, Connecticut owns and races the dinghy. He finished the boat with WEST SYSTEM Epoxy and has built his own carbon fiber foils.

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SAE Supermileage vehicle

Composites on Wheels

by Captain James R. Watson

Boats are my first love, but I get excited about projects like this Supermileage® vehicle, other SAE (Society of Automotive Engineers) and airfoil carved-foam bicycle. My job offers great opportunities to talk to some of the most talented and positive thinking people around: sculptors, inventors, rocket builders, and good ol’ boatbuilders. Folks who envision and tinker with a desire to experiment, improve, compete, make a living or just play around.  Continue reading

Building Composite Fan Shrouds

By Dan Witucki

Hopefully, you can stand one last story about El Niño. I work for Bay Metro Transit in Bay City, Michigan, and the long hot summer of 1998 was especially hard on some of our transit buses. Our 27′ buses are a front wheel drive unit, powered by a Cummins Diesel engine mounted below the driver’s seat.  We were experiencing dozens of air conditioning compressor failures, along with various other problems due to the overheating. While this was happening, the manufacturer also realized it had a problem, and equipped all subsequent buses with a fan on the side engine cover of the bus that sucked the hot air out of the engine compartment, curing the problem. Continue reading

Wood & Epoxy Car


Courtesy of Wessex Resins & Adhesives, Romsey, England

Peter Warner has always been interested in old cars. Late in 1990, he saw an old Citroen 2CV in a car scrap yard. After some negotiation, he paid about <£60 to have the “donor” vehicle delivered to his home. He wanted only the chassis, tires, wheels and the steering column. The old body was collected and taken back to the scrap yard one week later as part of the £60 deal. Continue reading

Jean-Yves Poirer's Zinnia

Readers’ Projects, Issue 8

Jean-Yves Poirier’s Strip-Planked Boats

Jean-Yves Poirier of Atyre, France, built these strip planked boats with WEST SYSTEM Epoxy. Above— ZINNA, a half replica of an English 19th-century racing dinghy, 18′ long, 177 sq. ft. sail area, 400 pounds. Below—NYMPHEA, an ultralight Thames rowing skiff, 23′ long, 145 pounds. Continue reading