Pattern-Coat Primer over Vac-Cast Epoxy Resin ?


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TURK
TURK
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Hi guys,



With reference to my 'Quad Headlight Project'.


I'm trying to remedy an issue I have .........  Basically,  I made two tooling plugs out of Vac-Cast Epoxy resin,  and because of the amount of shrinkage I got from the material,  my tooling plugs are 2mm too small.  What I'm hoping to do is to 'build-up' the tooling plugs by applying a few coats of Pattern-Coat Primer.  
Is This possible  ?

As a picture speaks a thousand words ( or in this case, a few pictures )  here's the process I used .......  I used CS25 Silicone rubber to make the moulds after I had made the original plugs.  I got shrinkage from the Silicone,  I then cast my 'Vac-Cast' Epoxy resin into my silicone moulds  ( got more shrinkage from the vac-cast resin ),  then I vacuum formed the parts I needed  ( headlight mounting brackets )  got more shrinkage from the 3mm ABS I'm using ........  the result is,  my ABS plastic headlight mounting brackets are 2mm too small all around their circumference !   Sad   >>

 





The vac-cast resin tooling plugs came out absolutely superb,  well chuffed with that  BigGrin   and my very first vacuum formed parts  >>

 



After I cut and profiled the parts things were looking very good indeed  >>

 



And with the headlight units installed  >>

 



Then comes the assembly ........  the parts I make will fit the OE headlight retainers,  as you can see from the red arrow there's a 4mm gap  Angry
As I only need the 'footing' or base of the part to fit inside the headlight retainer,  I'm thinking I could simply apply a few coats of Pattern-Coat Primer around the base of my tooling plugs to close that gap  .......  do you think this would work ?  >>

 







This fix is only a temporary measure guys,  until I get the dimensions correct,  once the bracket fits in there correctly I'll simply make some more silicone moulds with these 'fixed' tooling plugs.

The entire process is here >  T4 Quad Headlight Project









GO

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