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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Rich (Staff)
Rich (Staff)
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Hi Turk,

826cm2 equates to 0.0826m2 - so you'll be looking at around 80-90g (0.862 x 1kg) of pattern coat to cover at a thickness just shy of a mm. You'll be sanding and fairing back through this so your final thickness per layer is likely to be a lot less than this.

Generally though, it will use as much as it requires, the first coat especially may draw into the MDF if it is unsealed and it is likely that you'll need to apply a few applications to achieve a flawless finish and there may still need to be some filling with body-filler between stages to ensure that you have a smooth transition between sections of MDF. Smile

Remember that, as with all resins, temperature can have a big effect on the cure speed so if it is particularly warm where you're working, you may want to use a slightly lower catalyst ratio to slow down the reaction and to give you more working time.

Edited 11 Years Ago by Richie
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