So today i continued on with the hold repair.
This hold is originally chopped strand fiberglass and polyester resin (aka fiberglass resin from the bondo cans sold in most home and auto stores).
I refuse to use polyester resin as if its not used properly and over time it'll cause some serious health problems (and it stinks), epoxy is slightly better, but still needs properly ventilation and working habits.
So first up is taking some 30 grit sandpaper and scuffing up all off the new bonding areas Very well. Epoxy needs a mechanical hold on polyester, so the coarser paper the better. This then all gets triple cleaned with Acetone.
For the areas of the inner liner that were only broken free at the glue joints, i cleaned those areas out with 30 grit and acetone as well.
I then used some Hysol E20HP to bond the inner reinforcements back to the outer skin. This is an adhesive that i keep on hand, but its expensive at $18 for a 50ml tube. So its not something most would have to use.
For the gaps along the side innee liner, i cut off the shredded edges and then sanded these edges to a taper about 1/2" wide. Then i super glued some balsa wood sheeting on the inside the liner panel. This provides a flat surface for the fiberglass to sit on.
I also roughened up 2-3" past the tapered areas and again cleaned with acetone.
6oz fiberglass was then cut to extended about 1/2 way into the roughened area past the taper on either side of the gap. Then more 6os glass was cut and places inside the gap only. This was all done with epoxy at once. After 3-4 pieces in the gap, another piece slightly smaller than the very first was put in. Then more glass in the gap only. Once the area of the gap was filled in enough to nearly match the original thickness, a piece of 6oz Slightly larger than the very first piece was put in place. I then placed a piece of 1.4oz fiberglass over the entire size of the roughened area on. Peel ply was then put in place and it was all left to cure.
Once cured, the peel ply was removed and the repaired areas are now ready for primer and sanding... Eventually (picture of the repaired areas coming tomorrow).
this now left just the front portion of the inner liner missing. Replacing this is similar to the gapped areas. You need a surface to apply the glass. For this i used some regular white styrofoam insulation. It was cut to a shape i liked and glued in place with a hot glue. After much test fitting, sanding, rinse, repeat, i had it fitting how i wanted with zero interference with the headlights and radiator support.
Then it was just a matter of putting some 6oz glass over the entire piece of foam and along the cleaned/roughened areas of the original hood. I used about 6 layers of 6os fiberglass and 1 layer of 1.4oz glass. This was all covered in peel ply as well.
Tomorrow the peel ply can be removed and some epoxy/phenolic microballoons applied to the front lip. This mixture of stuff is more an asthetic thing than anything as it'll be used to flatten the forward lip to provide a uniform thickness.