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  #46  
Old 12-04-2007, 06:32 PM
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NICE!!!

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  #47  
Old 12-04-2007, 06:37 PM
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Looking good!
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  #48  
Old 12-04-2007, 07:08 PM
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Nice progress so far... and thanks for shrinking the pics
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  #49  
Old 12-04-2007, 08:52 PM
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Bill,
Put the thing IN the oven, set at like 200 degrees for a few minutes. The more even heat will likely reduce bubbles a bit. just make sure the lexan is propped up on something so it doesnt touch the grating
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  #50  
Old 12-05-2007, 05:56 AM
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looking good man! are you using a vac? or just gravity to pull it down?
now you got me all jacked up and wanting to start on mine
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  #51  
Old 12-05-2007, 01:07 PM
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Quote:
Originally Posted by superru View Post
looking good man! are you using a vac? or just gravity to pull it down?
now you got me all jacked up and wanting to start on mine

That was using a kitchen drawer to hold the headlight, while I put massive amounts of pressure on the plastic to form. I should have let it heat up for about a minute longer so it would be easier to stretch.

Next time I'm gonna try the vac method though.
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  #52  
Old 12-06-2007, 08:34 AM
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now you got me all jacked up and wanting to start on mine
Ditto. Insert drooling smileys here...

Or better yet, you have me eager with anticipation for when you start selling... I call first in line!
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  #53  
Old 12-06-2007, 06:36 PM
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I started making a Vacuum Form Mold Machine, and made a negative(I think) mold of the headlight. That's so I can use the negative mold of the headlight to make a positive(I think) mold of the headlight to use for the vacuum forming. The aluminum rectangle is one of two that I made so I can clamp the lexan to, to stretch over the mold.

I'm using the idea from here


Now onto the pictures.


My mixer bottle, an old wiper fluid bottle.




The frame used to hold the Lexan in place for forming.




Letting the plaster harden a little before I set the headlight into it. I took an eBay shoe-box and cut it in half longwise to make two halves for each headlight molds.




I had to press the headlight down because I put it in the plaster a few minutes too late. It was about the consistency of play-doh when I put it in. The plaster kept pushing the headlight out unless I kept pressure on it. I used saran wrap to seperate the headlight from the plaster to make pulling it out easier.






The negative mold should be hard enough by now to make the positive mold. I'll post pictures once I get everything set-up.
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  #54  
Old 12-06-2007, 06:37 PM
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looking good man

Tom
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  #55  
Old 12-06-2007, 07:21 PM
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Here's some more pictures. I just poured the positive mold of the headlight.


I just pulled the headlight out of the plaster. I shaved a little of the plaster off along the "bottom" of the headlight in the mold. To make the removal of the positive mold easier.




Layed down the saran wrap for the positive mold.




Just poured the plaster for the positive mold.




Once the positive mold is hard enough, I'll take it out and do some sanding to shape it up.
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  #56  
Old 12-06-2007, 08:09 PM
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Hmmm...Looking pretty good dude

If you havent done one for the other side yet...Try using dish soap as a mold seperator instead of the plastic wrap to avoid having to do too much sanding

Otherwise, damn boy, your making some progress!!
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  #57  
Old 12-06-2007, 08:17 PM
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Hey look its OT doing the tutorial http://www.youtube.com/watch?v=hGBRiYhxRTM
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  #58  
Old 12-06-2007, 10:07 PM
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I think I'm going to take your approach Eric, and re-do this mold using dish soap. It won't be as wrinkled and leave me with less sanding to do. This project is taking shape and coming along pretty well I must say. If it continues this fast, I should have the first set finished and installed by late next week.


Whoever was interested in a set, if you want one speak up, we can start the sign-up list now.

I've decided on a price as well,based on the amount spent on materials, time spent working on this, and the overall product itself. $75 plus shipping(shouldn't be much) to anywhere. I know you'll want to see the finished product first so I won't take any money now, only once they're finished.
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Last edited by 94SubieSVX; 12-06-2007 at 10:26 PM.
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  #59  
Old 12-06-2007, 10:22 PM
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Get A Freaking Heat Gun!

If you stretched it all first and then used some heat the plastic wrap/ plaster mold thing would have had much better results. I have done many things like this in the past and will just say that you are a few tries away from attaining what you are wishing for. As you have seen, you need a smooth mold to get a smooth cast. Plastic wrap will work if stretched taught. Otherwise you get the old man syndrome...
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  #60  
Old 12-06-2007, 10:24 PM
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Quote:
Originally Posted by YourConfused View Post
If you stretched it all first and then used some heat the plastic wrap/ plaster mold thing would have had much better results. I have done many things like this in the past and will just say that you are a few tries away from attaining what you are wishing for. As you have seen, you need a smooth mold to get a smooth cast. Plastic wrap will work if stretched taught. Otherwise you get the old man syndrome...

The plastice worked well when I used the actual headlight to make the negative mold, since the pressure was on it all at once. But for the positive mold, there were lots of tight angles and trying to get the plastic to form fit was hard, even when I was tapping the whole mold to get the are bubbles out.
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