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 9 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 8 Years Ago HOT Post Details
Group: Forum Members Posts: 101, Visits: 662	Hi guys, Thought I would update my quad headlight project, and show how my moulds worked out. I'd also like to take the opportunity in thanking some of the guys on here and the guys at 'Easy Composites' for their help. I haven't quite got to the carbon fibre stuff that I'm going to make, like the headlight covers ........ still designing the headlight mounting brackets right now. And they'll be vacuum formed. But things are looking promising, hope you like. I'll begin by the vacuum formed headlight brackets. Moulds were constructed of 9mm MDF, covered with Pattern-Coat-Primer >> Here's what the assembly looks like from the back >> Then it's just a case of installing the headlight units. After much research I decided I would be using the Hella Modules, very very good quality and excellent performance and the correct pricing >> A while back I had already made some basic headlight covers for testing purposes, using the original headlight glass as my moulds >> Then it was a case of assembling everything >> I then ran a few tests. I had to design an 'upgrade wiring loom', with the addition of diodes as I wanted the quad headlight setup to have all four headlight units on in high beam >> The headlight switching test is a very basic test, just testing the potential of the wiring loom really, as bright as these look already I'm not getting the full potential of the Hella units right now, as they are powered via a computer power supply. So just under 12 volts at 16amps >> Then I had to check the fitting to my van, yes ........ it's a VW T4 Transporter folks ! >> All in all, I'm very happy with the outcome ......... still got a few things to work out yet, but things things are looking very promising Loads more pictures of the project here > VW T4 Transporter Quad Headlight Project TURK Tags VW T4 Transporter Quad headlight Project
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Quad headlight project - MDF plugs for vacuum forming

TURK - 9 Years Ago

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

Dravis - 9 Years Ago

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

TURK - 9 Years Ago

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

Dravis - 9 Years Ago

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

TURK - 9 Years Ago

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

Dravis - 9 Years Ago

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

Dravis - 9 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 - 9 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) - 9 Years Ago

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

TURK - 9 Years Ago

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

Rich (Staff) - 9 Years Ago

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

Dravis - 9 Years Ago

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

TURK - 9 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) - 9 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 - 9 Years Ago

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

Dravis - 9 Years Ago

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

TURK - 9 Years Ago

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

TURK - 8 Years Ago

where you bought these lenses? any link or price

TomDesign - 8 Years Ago

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

TURK - 8 Years Ago

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

Nightfox - 8 Years Ago

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

TURK - 8 Years Ago

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