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Front turn signal light covers project by seajai
Started on: 01-09-2016 01:46 AM
Replies: 58 (2532 views)
Last post by: seajai on 10-11-2016 12:38 AM
seajai
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Report this Post01-24-2016 11:23 PM Click Here to See the Profile for seajaiSend a Private Message to seajaiEdit/Delete MessageReply w/QuoteDirect Link to This Post
Time for an update:

Both molds are done and ready for a production run:



I finally figured out what was causing my pock mark issue......dust! The kind of dust you can only see when the sun is shining in the window. Acrylic is really prone to static buildup, and the 18% humidity in my garage was only making it worse. No matter what I tried I couldn't stop the acrylic from acting like a giant dust magnet. I got the humidity up to 35% and even put a pan of water in the oven but nothing would stop the dust. After a dozen tries I finally found something that worked.......Plasti-Dip. There is a product out there specifically designed to protect acrylic throughout the thermoforming process, but it's not cheap, so I thought I'd try Plasti-Dip a substitute. It works quite well and eliminates 99% of the dust divots.

Blank coated and ready to form:



Formed:



Peeled:



Cut and ready to install:



Overall I'm happy with the final product, they aren't perfect, but pretty close. I will start a sale thread in the mall. http://www.fiero.nl/forum/Forum4/HTML/073403.html Please check it out on contact me if you'd like to purchase a pair.

[This message has been edited by seajai (edited 01-24-2016).]

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Dylpro
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Report this Post01-25-2016 12:42 AM Click Here to See the Profile for DylproClick Here to Email DylproSend a Private Message to DylproEdit/Delete MessageReply w/QuoteDirect Link to This Post
Very cool! I may be in for a Formula set when they come around
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Slammed
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Report this Post01-25-2016 03:36 AM Click Here to See the Profile for SlammedClick Here to Email SlammedSend a Private Message to SlammedEdit/Delete MessageReply w/QuoteDirect Link to This Post
A much faster and cheaper solution is to leave the outer sheet on the bottom. This will only work if you can heat from above and the sheet hasn't been scratched.
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seajai
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Report this Post01-25-2016 09:39 AM Click Here to See the Profile for seajaiSend a Private Message to seajaiEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by Slammed:

A much faster and cheaper solution is to leave the outer sheet on the bottom. This will only work if you can heat from above and the sheet hasn't been scratched.


Will it work with the paper coated acrylic or just the plastic film? I thought about trying it but thought it would just melt the protective film.
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Slammed
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Report this Post01-25-2016 01:00 PM Click Here to See the Profile for SlammedClick Here to Email SlammedSend a Private Message to SlammedEdit/Delete MessageReply w/QuoteDirect Link to This Post
Just the plastic. Every pull of acrylic I leave half wrapped

If you don't have an ir heater and have to remove the sheets, just use acrylic cleaner. It removes the static. And Don't blow with air as this creates static.

BTW, why are you using such a large sheet? For something so shallow, you can get away with less than an inch of trim. Get some half inch square tubing and remake your clamping frame. You'll save a ton of product

[This message has been edited by Slammed (edited 01-25-2016).]

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Rare87GT
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Report this Post01-25-2016 01:06 PM Click Here to See the Profile for Rare87GTClick Here to Email Rare87GTSend a Private Message to Rare87GTEdit/Delete MessageReply w/QuoteDirect Link to This Post
Very cool. I am in line for the Formula front and rear bumper covers (non-tinted most likely)! Also, don't forget what I messaged you about on the headlight covers


Thanks,
Amir

------------------


Best 1/4: 11.7 @ 115mph
Best 60ft: 1.60

[This message has been edited by Rare87GT (edited 01-25-2016).]

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seajai
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Report this Post02-18-2016 09:48 PM Click Here to See the Profile for seajaiSend a Private Message to seajaiEdit/Delete MessageReply w/QuoteDirect Link to This Post
Time for an update. Progress on the Formula lens covers has been a little slow but things are happening. Due to the long shallow area on the bumper I have decided to drape form the acrylic instead of vacuum forming it. This means the piece of acrylic will be cut prior to heating, after heating it is laid in the form and the other half is set on top to form it to shape.

To make the molds, I used a Formula bumper set flat on some saw horses. After filling the opening with ultracal30, I formed a plug to the compound curve of the bumper opening. Once that was set, I applied a release agent and covered the area with another layer of ultracal30 to pull a negative mold. I left that to dry for a few days and then applied 4 coats of wax as a release agent. Tonight I filled the negative mold full of ultracal30 to form the positive half. This will need to dry for a few days before I can run a sample lens to check fitment. If all goes well, I will repeat these steps 3 more times to make molds for the other lenses.

Here are a few pics, note the compound curves, these follow the bumper contours exactly. As a side benefit the curves should also add some rigidity to the long narrow lens. Stay tuned.......





[This message has been edited by seajai (edited 02-18-2016).]

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Slammed
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Report this Post02-19-2016 12:48 AM Click Here to See the Profile for SlammedClick Here to Email SlammedSend a Private Message to SlammedEdit/Delete MessageReply w/QuoteDirect Link to This Post
Looking good!

If you ever need to do body work or fill holes on the ultracal30, joint compound is the absolute best hands down
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Gwhite18
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Report this Post02-19-2016 02:38 AM Click Here to See the Profile for Gwhite18Click Here to Email Gwhite18Send a Private Message to Gwhite18Edit/Delete MessageReply w/QuoteDirect Link to This Post
Where's the like button?
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Danyel
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Report this Post02-19-2016 07:23 PM Click Here to See the Profile for DanyelClick Here to visit Danyel's HomePageSend a Private Message to DanyelEdit/Delete MessageReply w/QuoteDirect Link to This Post


------------------

Black Widow Build Thread 2007 - 2014 Tylers Toy
My Low Profile Buckets for sale My LED Sidemarkers for sale

[This message has been edited by Danyel (edited 02-19-2016).]

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Patrick
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Report this Post02-19-2016 07:38 PM Click Here to See the Profile for PatrickClick Here to Email PatrickSend a Private Message to PatrickEdit/Delete MessageReply w/QuoteDirect Link to This Post

I suspect the challenge is going to be improvising a method of mounting these relatively long "Formula" lenses securely without needing to modify/damage the nose itself.
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seajai
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Report this Post02-19-2016 08:04 PM Click Here to See the Profile for seajaiSend a Private Message to seajaiEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by Patrick:


I suspect the challenge is going to be improvising a method of mounting these relatively long "Formula" lenses securely without needing to modify/damage the nose itself.


Yep..... been thinking about a mounting method for a while.....not sure what to do yet. I think once I make an actual lens it will come to me. If anybody has a suggestion let me hear 'em.

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seajai
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Report this Post02-23-2016 11:43 PM Click Here to See the Profile for seajaiSend a Private Message to seajaiEdit/Delete MessageReply w/QuoteDirect Link to This Post
So here we go. I used the plug I made as a guide to make an MDF template for cutting the acrylic blanks.



With the acrylic cut to approximate size, I attach it to the MDF with tape and run it through a spiral flush trim router bit to trim it to the exact size needed. Next I used a round over bit to to radius the edges of the acrylic so it fits the rounded sides of the opening. I did a few test runs experimenting with oven temp and time to get the best results and this is the finished prototype.



It fits nicely in the opening and is recessed only slightly from the surface to the bumper. Here are a couple profile pics of the finished cover showing the compound curves.





The benefit of using an MDF template and a router to cut my acrylic is that I just need to flip the template over to cut the opposite side. So now with a successful prototype made I just need to cast the forming molds for the right front and both rears and make a router template for the rear covers and I'll have them ready to sell. (Oh yeah, and figure out how to mount them). Stay tuned
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Patrick
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Report this Post02-24-2016 01:04 AM Click Here to See the Profile for PatrickClick Here to Email PatrickSend a Private Message to PatrickEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by seajai:

(Oh yeah, and figure out how to mount them). Stay tuned


Just a little something to inspire you...

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Manitou
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Report this Post10-10-2016 12:15 AM Click Here to See the Profile for ManitouClick Here to Email ManitouSend a Private Message to ManitouEdit/Delete MessageReply w/QuoteDirect Link to This Post
PM sent
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Report this Post10-10-2016 09:24 AM Click Here to See the Profile for johnt671Click Here to Email johnt671Send a Private Message to johnt671Edit/Delete MessageReply w/QuoteDirect Link to This Post
I'd buy a set of front and rear cover for my 84 if you make them.
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JohnWPB
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Report this Post10-10-2016 08:32 PM Click Here to See the Profile for JohnWPBClick Here to visit JohnWPB's HomePageSend a Private Message to JohnWPBEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by johnt671:

I'd buy a set of front and rear cover for my 84 if you make them.


Been saying that myself since his last post in February 86 GT in my case though.....
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Patrick
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Report this Post10-10-2016 10:23 PM Click Here to See the Profile for PatrickClick Here to Email PatrickSend a Private Message to PatrickEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by JohnWPB:

...since his last post in February


Maybe you guys would be interested in the following thread in the Mall... Front turn signal light covers
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seajai
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Report this Post10-11-2016 12:38 AM Click Here to See the Profile for seajaiSend a Private Message to seajaiEdit/Delete MessageReply w/QuoteDirect Link to This Post
I won't be making covers for the bumper pad cars or the rear GT reflectors, I just don't have the R&D time right now. I already have enough projects stacked up to keep me going til next summer. I may at some point but not right now. If someone wanted to make a mold and send it to me, I will form up covers for you.

Follow my sale thread in the mall for info and updates.

[This message has been edited by seajai (edited 10-11-2016).]

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