Quad headlight project - MDF plugs for vacuum forming

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Quad headlight project - MDF plugs for vacuum forming

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TURK	TURK posted 11 Years Ago HOT Topic Details
Group: Forum Members Posts: 101, Visits: 662	Hi folks, Just a quick explanation of my current project. And a chance for me practice my skills at uploading pictures 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 ? TURK Tags MDF Pattern-Coat Primer Plug Quad headlights vacuum forming
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TURK	TURK posted 11 Years Ago HOT Post Details
Group: Forum Members Posts: 101, Visits: 662	Many thanks guys, Glad I got a couple of things right Would you think that different materials would cause the pattern-coat to set at different levels, such as brushing it onto MDF as opposed to on Glassfibre ? Interesting to hear that you found it to set 'abruptly' Dravis. I may go down to 1.5% in that case. What did you think I my unconventional way of working out the amount of resin required, such as ....... 1Kg of 'Pattern-Coat Primer' per 1m² which is 10,000 cm² 500g of resin - covers 5,000 cm² 250g of resin - covers 2,500 cm² 125g of resin - covers 1,250 cm² Is that the normal way people work it out ? Or is there a particular formula ? I am working with small quantities, after all, headlight assemblies are quite small compared to some of the things people are making on here, like car bonnets. The plugs that I'm making will be for vacuum forming, so hopefully they will be strong enough to vacuum form dozens of parts. I'm also working on the headlight covers, and will be making some out of carbon fibre, so plenty more questions will follow I'm afraid No doubt I will have to brush up on my math, as there seems to be a lot of converting to do. Now that I know I need 2% catalyst for my mix, I'm stuck with something else. I've bought one of those MEKP Catalyst dispensers, but it's marked out in millilitres ! So as an example, 10ml is equal to what in weight ? ....... 10 grams ? My entire project can be seen here > T4 Quad Headlight Project If you go straight to the last page you'll see the stage that I'm currently at. Thank you all folks, I feel I'm now getting somewhere with your your help. TURK
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Quad headlight project - MDF plugs for vacuum forming

TURK - 11 Years Ago

You need to work out / roughly calculate the surface area you want to cover with the primer. Then...

Dravis - 11 Years Ago

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

TURK - 11 Years Ago

No -No no -- You do NOT need the VOLUME -- You need the SURFACE area .. Cut out some soft cloth or...

Dravis - 11 Years Ago

[quote][b]Dravis (24/09/2015)[/b][hr]No -No no -- You do NOT need the VOLUME -- You need the SURFACE...

TURK - 11 Years Ago

Just some comments on your Bracket "Plugs" I assume that, since you are going to "pattern" coat...

Dravis - 11 Years Ago

1 square cm = 0,0001 square meter .. :cool:

Dravis - 11 Years Ago

Hi all, OK, I've worked out all the dimensions of all six sides. W=14cm x L=15cm x H=7cm all...

TURK - 11 Years Ago

Hi Turk, 826cm2 equates to 0.0826m2 - so you'll be looking at around 80-90g (0.862 x 1kg) of...

Rich (Staff) - 11 Years Ago

Hi Richie, And many thanks for taking the time to respond ;) Your math must be spot on as...

TURK - 11 Years Ago

Hi Turk, Yes, 5g equates to 2% of 250g. There is a degree of adjustability though, if you find it...

Rich (Staff) - 11 Years Ago

I have a constant 21 - 22 degrees in my workshop -- I use 1,5% for both the EC Pattern coats ---...

Dravis - 11 Years Ago

Many thanks guys, Glad I got a couple of things right :D Would you think that different...

TURK - 11 Years Ago

The density of MEKP is 1.0-1.15g/cm3 meaning that 1litre would weigh 1.0-1.15kg - as such, the...

Rich (Staff) - 11 Years Ago

[quote][b]Richie (25/09/2015)[/b][hr]The density of MEKP is 1.0-1.15g/cm3 meaning that 1litre would...

TURK - 11 Years Ago

If you want a totally gloss surface, you will end up doing a lot of sanding down, and re-applying...

Dravis - 11 Years Ago

I'll be sure to post my progress Dravis ....... or you can just follow the entire project here >...

TURK - 11 Years Ago

Hi guys, Thought I would update my quad headlight project, and show how my moulds worked out....

TURK - 10 Years Ago

where you bought these lenses? any link or price

TomDesign - 10 Years Ago

[quote][b]TomDesign (22/10/2016)[/b][hr]where you bought these lenses? any link or price[/quote]...

TURK - 10 Years Ago

Awesome work my friend Looking to do something similar as I have some Hella DE headlights for my...

Nightfox - 10 Years Ago

Thanks Billy, glad you approve ! :) Ah, yes ........ BMW E30 units, I see the high beam also...

TURK - 10 Years Ago

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