Molding Speaker pods a new way (for me)

[timcurtis67]

New to me anyway. In the past I have used shaped foam as plugs to create mold, sometimes plastic parts as well to create a mold.

I thought I would try it a new way that may even save me some time during the process. Manual labor time at least.

So I want to make a smaller version of these to fit in my buggy.

I 3D modeled the new smaller sized pods, This is one of them. The dashed lines so where the speaker and cup holder will be. I did the model work in Solidworks.

With the models I created more models of the mold I want to make. The teal colored part is one of the molds.

Then I took the newly created mold model and printed it on my 3D printer. A right and left side. Using PLA material with a fairly high layer height. I wasn't worried about fine detail yet.

Here is one of the finished mold on the printer table.

Here I am covering the printed molds with high build primer so I can smooth them all over the outside. That will be the finished inside of my fiberglass part when I pop it off the mold.

That's as far as I got so far. I'll post more pictures when I have the molds smoothed out. And pictures of the molding process, and final finished parts.

It looks like this will work this way, only time will tell. If it does it will stream line mold making for me for sure.

FYI the pods will be around 12" long by 7-1/2 high at the edge of the flange.
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67 Desert Fox Spoiler

[Dale M.]

Seems to me you could have just 3D printed pods and moved on, seems like a lot of extra step(s) to now make molds and then have to layup pods in glass and do grills and cutouts...

Or am I missing something here?

Dale
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“Fear The Government That Wants To Take Your Guns" - Thomas Jefferson.

"Kellison Sand Piper Roadster" For Street & Show.
"Joe Pody Sandrover" Buggy with 2180 for Autocross (Sold)
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All suggestions and advice are purely my own opinion. You are free to ignore them if you wish ...

[timcurtis67]

[62kellison]

are these for buggies with sidepods?.is there other places to put them without cutting into side of buggy?.i would like something like this but am not going with sidepods.

[timcurtis67]

Sorry, yeah these will on my car inside the pods. Not sure where you could fit some without pods to hid them.
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67 Desert Fox Spoiler

[62kellison]

I need to make or find some kind of center console that fits.Dale any ideas?.

[Dale M.]

[timcurtis67]

[GS guy]

Cardboard mock-up is the right idea.
Much easier to re-shape when that "cool" design you come up with doesn't allow your right knee to fit with foot on the accelerator!

Luan plywood is a nice material to work with for final product - ALA you want flat surfaces. It's light, cuts easily with a razor knife, sands well, nice and flat. Cover with 1/8" foam and some vinyl and give it a nice professional look.
Jeff
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70's vintage Deserter GS buggy - undergoing transformation to Super GS!

[Hot Air]

When using cardboard you do not have to make it all in one piece, Work with smaller sizes and until you get the shape you want and then tape them together. Once you have the layout transfer it to a one piece of cardboard and see if it will work. Tape it all together.
One thing to keep in mind is how to get it in the car one it is made. I hade made a couple designs until I found one that worked for me. I had to make it in two pieces to fit. Make sure your seats are in, made that mistake and had to re-due it.

Good luck
Len
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73' Bug
85' Porsche 911 Carrera 3.2