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djway3474
Samba Member
Joined: August 19, 2011
Posts: 2582
Location: The Real NDK So Cal
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 Posted: Tue Nov 25, 2014 2:14 am Post subject: Glove box fresh off the form |
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After a couple of years researching and testing materials I finally pulled the prototype glove box.
I have the texture inside and out to match the original. I did a water bead test and it resisted moisture for several minutes, but I hope to improve that.
Now it is time to make the actual form so I need to get a good fitting glove box to make the final form from.
It would not be hard to do this for bug, bus and ghia. 
I am so close to an actual box I am bustin out LOL 
the box in the ghia
this is a swatch off the form to check texture of the inside.
Once I get a good mold of a good box it will fit better. |
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djway3474
Samba Member
Joined: August 19, 2011
Posts: 2582
Location: The Real NDK So Cal
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| Posted: Tue Nov 25, 2014 11:15 pm Post subject: |
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I want to thank Loren and Scott Doonan for their help with this project. With all three of us on a mission, what can stop us? 
Here is another shot inside the box after a little more massaging of the box and some more cure time.
Here is the color and texture of this box compared to an original fragment off a later model.
Finding a consistent supply of material that has the same color will be my biggest problem after the last few form issues are worked out.
The box is VERY rigid and another water test looked good. I soaked it in hot water for 10 minutes and there was only minimal absorption. |
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aerosilver
Samba Member
Joined: July 29, 2006
Posts: 882
Location: UK
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| Posted: Tue Nov 25, 2014 11:27 pm Post subject: |
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Nice work  |
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bluedot
Samba Member
Joined: April 25, 2013
Posts: 439
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| Posted: Wed Nov 26, 2014 12:25 am Post subject: |
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| Wow! |
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sputnick60
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Joined: July 22, 2007
Posts: 3916
Location: In Molinya Orbit
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paul_round
Samba Member
Joined: October 17, 2014
Posts: 502
Location: UK
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| Posted: Wed Nov 26, 2014 7:25 am Post subject: |
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| +1 for RHD |
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c21darrel
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Joined: January 22, 2009
Posts: 8211
Location: San Dimas
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kiwighia68
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Joined: October 20, 2013
Posts: 2875
Location: Auckland, New Zealand
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| Posted: Wed Nov 26, 2014 1:18 pm Post subject: |
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Make that +2 for RHD
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oldbusboy
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Joined: June 25, 2006
Posts: 604
Location: Bowen Island, BC Canada
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| Posted: Wed Nov 26, 2014 3:38 pm Post subject: |
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Awesome work.
Sign me up for 1 when they are ready.
Trevor
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djway3474
Samba Member
Joined: August 19, 2011
Posts: 2582
Location: The Real NDK So Cal
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| Posted: Wed Nov 26, 2014 4:58 pm Post subject: |
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Does anyone know someone that would like to distribute these world wide? I know how to do them commercially and even found some companies that can probably do it. But it is a lot of up front cost and time, and you must run large numbers to get cost done. I would gladly work with someone to get this going. Bus, Bug and Ghia can all be done.
RHD guys I would like to help but I would need something off of which I could make a form. Then it needs to be test fitted et cetera. Lots of time and energy I don't have. I will keep it in mind if I find an easier way.
These things are VERY labor intensive and will probably take about a week per box in days and have many, many hours time wise per box. It is all done by hand.
I like to help the VW community bring cars back to their glory. The other parts I made were nothing compared to this box time wise. I am only tackling projects on parts that just can't be found to bring my 59 back to life and then help as many as I can.
I am not a business, just a guy trying to get the job done.
Once I have made a few I will update and see what I can come up with. |
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jpjohns
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Joined: May 03, 2014
Posts: 882
Location: Harrisonburg, VA
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| Posted: Thu Nov 27, 2014 11:04 am Post subject: |
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What are they made of...looks like recycled paper.
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"Scrapyards are for quitters" - Beetlenut (a Samba member) |
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John Moxon 
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Joined: March 07, 2004
Posts: 13955
Location: Southampton U.K.
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| Posted: Thu Nov 27, 2014 11:55 am Post subject: |
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| djway3474 wrote: |
| Does anyone know someone that would like to distribute these world wide? |
Well I'm sure you've already thought about the obvious Dwayne...Scott has a record of reproducing hard to find parts for KGPR so that's the first.
When I've been involved in repros I've found the VW magazines have been very helpful in getting the news out there but that's after the event. What you need of course is money to produce them in the first place. Production by subscription seems to be the only way without a professional sponsor.
You look to have produced an excellent, accurate but labour intensive product. The shape of the box looks like it would be an ideal candidate for 3D printing and that could also replicate the original texture, needing only to add colour in some way or other. If you had a 3D model producing LH or RH versions would be simple.
It's very nice to have a repro made in the same way as the original using the same materials. However you could be seen to be making things too difficult for yourself when the means to make a less costly but acceptable plastic repro exists.
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djway3474
Samba Member
Joined: August 19, 2011
Posts: 2582
Location: The Real NDK So Cal
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| Posted: Thu Nov 27, 2014 12:06 pm Post subject: |
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I would not put the plastic in a nice restoration nor would I use a 3d part.
With machine production these could be made at a very reasonable price.
For someone with a distribution system this would not be hard at all. I have done all the research and RnD so it is ready to go.
As I said before after I make a few and see how it goes I will try to help as many guys who want the original look in their cars as I can. RHD I would need a really good casting to start with.
My damn health is my biggest obstacle. |
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djway3474
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Joined: August 19, 2011
Posts: 2582
Location: The Real NDK So Cal
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| Posted: Thu Nov 27, 2014 12:12 pm Post subject: |
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| jpjohns wrote: |
| What are they made of...looks like recycled paper. |
All molded products of this type use pulp as the base. It all depends on the needs of the final product. Since the early 1900s they have been doing this exact process and using recycled product if varying degrees, again depending on the needs of the final product. There are various base products that can be started with that are developed from many plant sources.
Mixing and blending of substrates and additives must be adapted for each item as needed. |
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John Moxon
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Joined: March 07, 2004
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Location: Southampton U.K.
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| Posted: Thu Nov 27, 2014 12:29 pm Post subject: |
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| djway3474 wrote: |
I would not put the plastic in a nice restoration nor would I use a 3d part.
With machine production these could be made at a very reasonable price.
For someone with a distribution system this would not be hard at all. I have done all the research and RnD so it is ready to go.
As I said before after I make a few and see how it goes I will try to help as many guys who want the original look in their cars as I can. RHD I would need a really good casting to start with.
My damn health is my biggest obstacle. |
Not criticising in any way Dwayne...just playing "devil's advocate" to see if there's any alternative. Just concerned you'll end up burning the "midnight oil" trying to satisfying an unexpected avalanche of orders...I've seen that happen all too often.
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djway3474
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Joined: August 19, 2011
Posts: 2582
Location: The Real NDK So Cal
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| Posted: Thu Nov 27, 2014 12:43 pm Post subject: |
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No criticism taken John. One of the problems with these and using the additives is keeping it from looking like plastic. I'm just gonna do what I can. Now that my bus is painted I am going to concentrate on the Ghia now, no more distractions. I will help as many as possible.
Once I find a good set of dash handle seals I will make those too, and someone I know is working on the hood stops from the early cars.
The felt strip clips are also being researched since no one else has stepped up. I really wish they would since I really don't want to do it.
Last edited by djway3474 on Thu Nov 27, 2014 8:31 pm; edited 1 time in total |
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VeloMikey
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djway3474
Samba Member
Joined: August 19, 2011
Posts: 2582
Location: The Real NDK So Cal
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| Posted: Thu Nov 27, 2014 5:28 pm Post subject: |
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| The problem with 3-D printing is it leaves a sandcast finish so if you need a smooth finish the part has to be sanded. That will not work for the visors as the waffle texture cannot be touched. |
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djway3474
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Joined: August 19, 2011
Posts: 2582
Location: The Real NDK So Cal
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| Posted: Tue Jan 20, 2015 6:25 pm Post subject: |
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Well after many hours and more dollars than sense, I finally finished a working form and made a govebox that is very close to factory.
I wound up not being able to replicate the way they were made at the factory and had to do it all by hand. I know how to do it on a large scale, it just would not work at home. It was a ton of work but I think the results are worth it. The only down side is some of the materials I used to make the form are leaving little rust spots inside. I have a few ideas to stop that but the felting should hide it.
I even tinted the materials to try to copy that blackish cast of the original.
Here are a few pictures. The last one is an original box next to the reproduction.
A felting job on the interior should make that look even better. |
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ZENVWDRIVER
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Joined: November 07, 2008
Posts: 3340
Location: N.E. Oklahoma
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| Posted: Tue Jan 20, 2015 6:39 pm Post subject: box |
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...when I got my 1964 Ghia, back in November, 2014...it still had the original 50 year old glove box and upon removing it to then remove the grab handle, above it, I broke it 
...looked around for a genuine replacement, to no avail and so I stitched the original and re installed it...
The one you made is beautiful !
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