Flexible, durable finish for a wooden vehicle

Hi all,

I am on the home stretch of building an electric scooter. The fairing/body is constructed of laminated ply bent around a former.

The fairing is laminated in 4 layers - the middle two are a very open grain 4mm 4-ply called 'bendy ply', and the two outer layers are a very thin 2mm thin birch 4-ply (also called aircraft ply).

You can see the project on my blog: projectitis — Electric Scooter

I want to keep the timber look, so I am hoping to finish it in a clear/transparent finish rather than painting it. However, as you can image it has special characteristics:

1. Flexible. The scooter will vibrate and flex slightly as it is used.
2. Durable. The scooter will be out in the weather, and especially needs to be rain proof
3. UV resistant. Once again, in the weather means exposure to sun.

I have asked at the local Bunnings, but they don't know of anything suitable.

Although they didn't have any product suggestions, they said to look for a product also suitable for cane furniture, which also flexes and has similar finish requirements.

At the local fibreglass supply place they told my a clear gelcoat was not suitable as it has no strength and would crack with use and the weather. They suggested perhaps using surface tissue, which is a very thing fibreglass matt.

Any other suggestions?

Thanks very much!
Peter

Looks great. Just to let you know, your website isn't working from this end. Must be something to do with your DNS servers.

It was working earlier tonight. I went there maybe all the people looking has used up his allowance of MB.

I rang a local classic car restorer. He said he finishes wooden cars with 4 spray coats of Epiglass Everdure that penetrates the wood and toughens the fibers, and finishes with a PPG clear coat as used on cars. Apparently the Everdure is a marine product.

I rang a local car painter friend, and he recommended 3 coats of something called clear board sealer, followed by 2 coats of full gloss 2k urethane clear coat.

My only concern (with either of these) is that my scooter fairing will vibrate and flex more than a wooden car would, and the finish would crack.

Any thoughts?

Whenever I have to finish anything that I think is going to cop a lot of abuse, I head to a marine supply shop. I've had timber boats and the paints etc around these days for boats are great.

Of course, it is impossible to walk into a boat shop without spending at least $100.

A good quality marine varnish would stand up to the strain.

Good tips. I'll visit some marine supply places for product advice :)