Quad headlight project - MDF plugs for vacuum forming


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TURK
TURK
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Hi folks,



Just a quick explanation of my current project. And a chance for me practice my skills at uploading pictures  Smile

This is what I'm trying to make. The rough shape of the quad headlight cover was vacuum formed using my DIY vacuum former.





I'm still a long way away from creating the final product, I know. But a lot of things have changed since then. Namely the mounting brackets. The new design is a modular system, these plugs are made of MDF, I've had to use body filler to shape the draft angles, as I'll be using my newly acquired Formech 508DT vacuum forming machine.

Here are my MDF plugs for the headlight brackets >>







My first question to you guys would be, now that I've purchased some 'Pattern-Coat Primer' to cover the plugs with, is how to measure out ( or weigh ) how much pattern-coat primer I need the cover the plugs ?

Would I calculate the volume of the plug ? say, L x W x H ........ then what  ?



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Dravis
Dravis
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You need to work out / roughly calculate the surface area you want to cover with the primer.  Then work it out from the amounts in the info on the EC pattern Coat primer ..

I think you will need about 1 kg of it pr. roughly 0,7 sq metre ..   But that is not taking into account of sanding down, flattening and applying multiple coats.

Depending on the amount of catalyst you put in and your workshop temperature, be aware that it "sets" very abruptly-  My advise is to work fast and stop brushing as soon as you notice it thickening.

Good Luck!

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TURK
TURK
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Many thanks Dravis,

My MDF plugs are ready, all flatted, sanded, just ready for the Pattern-Coat Primer.

They're basically box shaped. 

(L)150mm x (W)140mm x (H)70mm

So I have to workout the volume of said part.

V=L x W x H ( V=15x14x7 ) to get the volume area in cm3

the total is 1470 cubic centimetres



I then converted that volume into weight and got 52 fl.oz ( imperial )

That's an awful lot of resin just for a small plug, that's over 2 pints per plug !

This is what I'm covering with one layer of resin >>



There's two in the picture, but in all I have four as they're modular construction. But I'll be doing them individually.
I'll apply more coats of resin if required.







TURK


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