Defroster ducts in ABS plastic

[frogman_94]

I'm getting my Thing ready for painting. When I took off the defroster ducts they were in bad shape.

I'm going to make a new set out of ABS plastic. I'm thinking of making a mold so I can easily reproduce them. Would anyone be interested in purchasing a set? I don't have a price yet. I'm just testing the waters.

[mondshine]

If you plan to produce these for sale, keep in mind that the air inlet (on the left side duct) is different between '73 and '74 models.

Good luck, Mondshine

[frogman_94]

[mondshine]

Well, good luck with it.

I will be curious to see how this turns out.

[Lleach9]

Farther down on my list, I have a similar plan for my 73, except trying to re-create them using fiberglass. I am very interested in how yours comes out, and it wouldn’t take much convincing to give yours a try instead.

Keep the updates coming.

[Dougster43]

I had some of the same ideas, but fortunately mine were in decent shape and I was able to make minor repairs with epoxy and then strengthen them up with a few coats of resin before painting. I might be interested in a set of ABS molded ones though...

[ncpi]

I would want some!

My heater was missing and I am going to install a setup from Thingparts...but I don't have defroster boxes/vents. Mine's a 73.

I might suggest asking Michael Basso if he would be interested in re-selling them, I bet he would. Good boxes are near impossible to find.

Bill

[frogman_94]

I made some wooden molds. I heated up the ABS with my heat gun and did my best to form it around the mold. It didn't go as planned. I have to rethink my process.

The best way to do this would be to make half molds and do a vacuum mold process. If you look at the original duct they are made with two halves. I don't have the room to undertake that.

I'm going to make a mold out of steel sheet metal. I have a brake at work and can bend sheet metal easily.

[ncpi]

[SilverThing]

I've toyed with the idea of making my own defrost ducts as well. I've been leaning towards either metal or a composite (fiberglass), but haven't actually started the project.

My concern with using ABS plastic is will the ducts deform or melt with hot defrost air running through them? My gas heater output gets warm enough that I'd be concerned about that.
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"I like how everyone likes talking about Zeke's Thing yet he's the only one that's ever seen it." - Katie
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[frogman_94]

Looks like I'm going to make the ducts out of sheet aluminum. I mocked them up in Solidworks and had to make a couple of adjustments. I think I have the final design.

[ncpi]

Keep me posted...I still need a set

[Hyatt181]

I’d love someone to make a splitter for the outlet on the gas heater.
The heat coming out on just your right foot makes for a fun drive. I’d tried to find a t made out of silicone to use but haven’t found the right shape.

The outlet temp there gets to about 300f.

[BNMike]

[low-viz]

I'd be interested in a set. My '72 mil-spec (gas heater) doesn't have any ducts at all. (still looking for a timer module as well)

[frogman_94]

It's been a couple of years and I decided to 3D print the defroster ducts. Since I had to model them I said why not make them better. Here is what I came up with. I'm going to print the center section first to check the size and the location of the opening where the ducts connect.

[BugBusGhiaThing]

This looks really nice - definitely more thought out than the original. It appears this design might drive heat to the edges of the windshield more efficiently. And, if it isn’t made of cardboard, call it a bonus!!

[BNMike]

[frogman_94]

The first piece is printed and I have to make some adjustments to the model so it will print easier. The oval duct will be printed separately and glued. I also eliminated the step on each end. These were are the joint for the next piece. I'm also going to print the joints separately and glue them. I removed the little tab too. I don't think I need it. The screws from the top should be enough to hold it.

[frogman_94]

I'm also thinking of making this so it doesn't blow hot air right on your foot.