Mine Projekt!

pinealservo · Posted: Sat Apr 23, 2011 10:05 am Post subject:

Carbon fiber is a lot more expensive than ABS and gives you a very rigid part. ABS flexes, which is a good property for something that can potentially be hit by high-speed rocks. Fiberglass bumper covers crack, ABS bumper covers don't. It's a good material to use on the front of your car, and with the techniques in the link I posted, it's at least as easy to use as fiberglass for small parts. It might be harder to do a full bumper cover with vacuum-formed ABS at home, but for those little fog lights it would probably be easier.

I'd like to see the fiberglass Vanagon bumpers reproduced in ABS, which would put an end to cracking problems, but I don't like the idea enough to actually pursue it right now. Smile

r39o · Posted: Sat Apr 23, 2011 10:51 am Post subject:

I like RIM plastic. It deforms and pops back. I think the investment in tooling precludes most small runs from using that material though.

How about cast in a flex resin? Cheap to do....
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r39o · Posted: Sat Apr 23, 2011 10:56 am Post subject:

Crankey · Samba Member Joined: July 11, 2004 Posts: 2659

I like fiberglass cause it can be repaired with fiberglass. I mention the vacuum bag thing because I've seen it done before and it made a nice smooth part w/o alot of cleanup. but black resin and fiberglass is good too.

if I had a set of original housings, I think I'd find a pair of lamps that would work in current production and fit them to the frames and make the bezels work (i.e. bondo in the currently made lamp bezel) then go ahead and mold the modified part.

I'm running an SA lower grill now so it kinda takes the edge off my desire for this. to me it's all just an aesthetic part cause I drive in the city 99% of the time. I wouldn't mind having a set of them on the shelf though, just to change it up sometime Smile

r39o · Posted: Sat Apr 23, 2011 1:57 pm Post subject:

Nothing says you have to have a rectangular lamp in the hole.

You could, for example, fit a tiny round DE lamp. Would match the round head lamps lots of us use. Fill the void with more material.

Also, some other stockish little square lamp could be fit. Say a fog lamp from an A3.

Come to think about it, you could just fill in the empty area and let the user mount their own lamp. Or nothing at all.

Using fiberglass would allow the end user to modify has that person chooses.

Just some idears.
_________________
"Use the SEARCH, Luke" But first visit the Vanagon FAQ!

1990 Multivan EJ 22, Rancho trans 0.82 4th, Small Car front AC, CLKs w/ 215/65-16, homemade big brakes 303mm, Konis, Recaros, etc....

Click to see my ads for Cup holders, Subaru clutch fix and CLK wheels (no wheels currently)

levi · Posted: Sat Apr 23, 2011 2:57 pm Post subject:

r39o · Posted: Sat Apr 23, 2011 3:28 pm Post subject:

levi · Posted: Sat Apr 23, 2011 4:32 pm Post subject:

okay okay, HERE :

"use the search Luke"

http://www.thesamba.com/vw/forum/viewtopic.php?t=449914&start=60
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Crankey · Samba Member Joined: July 11, 2004 Posts: 2659

r39o · Posted: Sat Apr 23, 2011 6:34 pm Post subject:

Classicvibe · Posted: Mon Apr 25, 2011 9:31 am Post subject:

Well, it looks like that guy has stepped up on the flare project which is pretty awesome. I like the idea of the vacuum plastic and I may try that myself just for fun, and pursue a different light option. I would love a high efficiency modern light in that position. I would probably use a modular fitting for the light area, and make a couple of different options, one for a standard/Common Hella type lamp, square for the folks looking for that, and another that was round, a more modern look to match the SA grill. I will keep studying up on the vacuum method as well as some standard lights to fit. If anyone knows something about new optimal lights, or some more plastic help lemme know.
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otiswesty · Posted: Tue Apr 26, 2011 11:34 pm Post subject:

Repro surrounds

http://www.thesamba.com/vw/classifieds/detail.php?id=1109758
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r39o · Posted: Wed Apr 27, 2011 10:09 am Post subject:

Classicvibe · Posted: Wed Apr 27, 2011 4:06 pm Post subject:

pinealservo · Posted: Wed Apr 27, 2011 7:54 pm Post subject:

If you're serious about doing some repros, you should probably pick up some mold material and make some molds before you install them. You could fill in the light holes with non-drying modeling clay, then make plaster negative molds. The same site I listed for vacuum forming instructions has a plaster mold-making and casting howto as well: http://www.studiocreations.com/howto/stormtrooper/index.html

With negative molds, you could immediately make a fiberglass reproduction with a flat surface instead of a light, or you could make a foam plug with expanding foam that you could carve out for a different light fixture, then make a new negative mold. From that negative mold, you could cast a plaster (or other hardy material) plug for vacuum forming.

I imagine there would be enough demand here for fiberglass reproductions with a flat surface instead of a hard-to-fill light hole to make back the cost of the plaster, clay, foam, etc. and maybe even finance the construction of your vacuum forming machine. Smile

While you're at it, you could make a Stormtrooper costume and be a hit next Halloween!

Crankey · Samba Member Joined: July 11, 2004 Posts: 2659

I don't think I'd bother re molding for the flat surface. just cut it out and 'glass it up.

you'd need a hole to fit whatever light you find that would work, so just place the new lamp bezel in the hole and 'glass up the margins, bondo a fillet on the front side sand and paint.

Masta Shake · Posted: Mon May 02, 2011 9:48 pm Post subject:

I have the Zwos and love em. Make sure you run a relay...Mine was wired through the switch. That's a lot of power through the switch.
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kamzcab86 · Posted: Mon May 02, 2011 10:22 pm Post subject:

I don't think those will look too good on yours; I'd be happy to take those things off your hands. Anxious

I was tempted to take my tools out at SyncroFest Laughing

... a couple of vans there had them.
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otiswesty · Posted: Mon May 02, 2011 10:41 pm Post subject:

madspaniard · Posted: Wed May 04, 2011 9:14 pm Post subject:

Projekt Zwo foglight guards arrived from Germany, will be installing soon

Image may have been reduced in size. Click image to view fullscreen.

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