I want to make a one-piece body, but I don't have the space to do it in one go.

I don't have a great deal of experience working with GRP, so was wondering if it would be okay to make the four quarters independently and then join them all... next question I suppose - what would be the best technique for joining GRP panels to maintain strength?

Cheers

You mould a lip at the panel joints and then join by bolting through.

Was hoping to have smooth seams.

if you do it that way you could then fill the seams with filler.

other way i guess is to line all the panels up PERFECTLY, and then layer fibreglass over the inside of the seams. 3 layers. then filler over the top again

Gaffer tape

Caber

As above, use the 'glass tape' method. Position panels in a good butt join and apply a 100mm strip of fibreglass mat behind the join. Then fill the front of the join with filler and sand down to a smooth finish, apply hi-build primer and paint.

*edit* You can always apply flowcoat to the inside when all the joins are done - that will make it opaque, hide the surgery marks and make it a bit stronger too.

[Edited on 17-10-07 by RazMan]

oooh, and you said about panel strength. get some paper rope, and fibreglass that in to form fibreglass ridges to add some strength

Be carefull with butt-joining two parts together, and only applying glass on the rear. Eventhough you will put filler over the gap, in due time the gap will work its way through the filler, and show through the paint (at least it does on my car; and the proper filler has been used). Best thing would be to add a glassfibre strip on both sides.

Imagine you are joining heavy steel plate, you would chamfer the edges so you get penetration(ooooerrr..) same applies with grp. chamfer both edges then use summat to hold both faces inline but with a wee gap...gel coat the join from the inside so this penetrates the gap...bit like using it as glue if yer like then lay up the inside with a good over lap but key the matting first and wipe it with acetone or it WILL fall apart.......once cured the gel coat ridge can be flatted and hopefully polished if the joins are good enough.......easy really

Mark.