How Fiberglass Parts are Made

fiberglass workshop 1 thThis is the shop where Phil Little stores his molds. All the molds you see were made from hand-built patterns by Phil. Phil was (and is) an advertising guy when he started making fiberglass parts for his flat track bikes and for race friends. Half of these molds were made when Phil owned Omar’s Dirt Track Racing. That company was sold to a California man but the molds always stayed in Minnesota because there are so few fiberglass companies across the nation who mess with small parts. The California guy went bust and Phil’s glass guy now owns the parts and sells them at The other molds are active for Phil’s current company, Phil Little Racing.

fiberglass process 1 thParts start here with a mold. Its interior is coated with dedicated waxes as the release agent. (This of course is not a Storm part.) The Storm is made with four parts; tank top, tank bottom, tail and seat base.

fiberglass process 2 thColored gelcoat is sprayed into the mold first. These molds are tank tops for Phil’s SXR Street Tracker dedicated for Evo Sportsters up to 2003.

fiberglass process 3 thFinally fiberglass/resin is sprayed into the mold where it cures in about a half a day. This part has had the excess glass strands trimmed away. This is usually done with a Stanley knife when the matrix is semi-hard.

fiberglass process 4 thHere is the new born part out of the mold. It’s surface will have micro flaws which go away if the owner sands for painting. When a part is done in colored gelcoat like this one Phil will sand the part with 2000 wet/dry then polish to a high luster with a 3M micro polish.

fiberglass process 5 thHere are Storm parts fresh form the mold destined for Allan Ingles in Vancouver. His were done in white (which is cheaper the colors) when the parts are to be painted.

  • [Site updated January 6]

Fiberglass Warning

More than a few parts I offer do not met DOT or SAE guidelines for safety. This is especially true of my fiberglass gas tanks. Metal tanks crush upon impact. Fiberglass can break and leak upon impact. This of course is a source of fire and a danger to you and others.

By purchasing any of my tanks (and other non-compliant DOT and SAE parts) you are assuming the risks of danger, injury and death. If you will not accept the risks, don’t purchase my products or return them unaltered for a refund.