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Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic
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Solomon Grundy
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PostPosted: Fri Oct 28, 2016 5:20 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Fresh off the griddle. I should have 4 ready by next weekend.

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PostPosted: Sun Oct 30, 2016 6:25 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Any chance of you making the 481 script?
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Solomon Grundy
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PostPosted: Mon Oct 31, 2016 4:30 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

I assume you are talking about this unit.
This test did not work out so well. The material is too thin and warps.
The only way I can think of putting it on the car is to glues it; otherwise it would be too fragile. Even a magnetic backing might not stay.
Maybe mounting it on a plate or something else to stabilize it; but that would ruin the effect.
I have some other ideas about the 481 but have not had time to implement it yet.

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PostPosted: Tue Nov 01, 2016 5:38 am    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Solomon Grundy wrote:
I assume you are talking about this unit.
This test did not work out so well. The material is too thin and warps.
The only way I can think of putting it on the car is to glues it; otherwise it would be too fragile. Even a magnetic backing might not stay.
Maybe mounting it on a plate or something else to stabilize it; but that would ruin the effect.
I have some other ideas about the 481 but have not had time to implement it yet.

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That is the one I was referring to. I like that one a lot, but I'll keep watching to see what you come up with that is more durable.
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PostPosted: Fri Nov 11, 2016 9:04 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Have you ever hit the printer and too many come out?! Any takers? PM me if you are interested.
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PostPosted: Fri Nov 25, 2016 2:31 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

How can I get a couple...
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mark tucker
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PostPosted: Sat Nov 26, 2016 1:00 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

hmm I gotsa idea..... any body ever used or seen a K&N stub stack?? usualy made for hollys & other carbs to increase the cfm&performance.....some for our vw's wood be nice....for many diferent carbs&combos.kinda like almost free hp. so you 3d guys get to work!!!(the webber idf stuff needs a better stack then the steel ones that eat the filters and have to be removed to change jets) 3d tops countoured would also be nice to add more cfm.
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PostPosted: Sun Nov 27, 2016 12:23 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Interesting ideas, but unfortunately even though I have the CAD tolls at hand & 3D Printer, I do not have the expertise in fluid dynamics to set such a flow analysis up. Maybe one of the Volks in this group have technical expertise. Wink
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mark tucker wrote:
hmm I gotsa idea..... any body ever used or seen a K&N stub stack?? usualy made for hollys & other carbs to increase the cfm&performance.....some for our vw's wood be nice....for many diferent carbs&combos.kinda like almost free hp. so you 3d guys get to work!!!(the webber idf stuff needs a better stack then the steel ones that eat the filters and have to be removed to change jets) 3d tops countoured would also be nice to add more cfm.

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PostPosted: Wed Nov 30, 2016 7:21 am    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS pla Reply with quote

Solomon Grundy wrote:
Not sure about production but I will certainly send the STL files to anyone who asks so they can 3D Print it if they wish.


Please send me the STL file! [email protected]. Thanks in advance!
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PostPosted: Wed Nov 30, 2016 12:27 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

anymore KDF emblems available?
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Solomon Grundy
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PostPosted: Wed Nov 30, 2016 5:13 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS pla Reply with quote

I will email you also but if you follow the topic the 181-KDF file is at
https://goo.gl/U0gVNq
This is an STL file that anyone with the equipment should be able to print.

Taliesin77 wrote:
Solomon Grundy wrote:
Not sure about production but I will certainly send the STL files to anyone who asks so they can 3D Print it if they wish.


Please send me the STL file! [email protected]. Thanks in advance!

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VW 181 Archive: https://sites.google.com/site/jeffgilleland/vw_archive
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Solomon Grundy
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PostPosted: Thu Dec 01, 2016 10:47 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

YEP, please PM me fro these fine 181 custom emblems. Cool
jmstu76 wrote:
anymore KDF emblems available?

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VW 181 Archive: https://sites.google.com/site/jeffgilleland/vw_archive
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Welt
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PostPosted: Thu Dec 15, 2016 10:52 am    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Doing some test prints with a Projet 3600, got lazy with modeling and used that nicely shared KDF style STL. Printed with coarsest setting in wax.

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I think I'll use that print as a master model and make a wax injection mold out of silicone or polyurethane -> wax patterns for investment casting. Of course, I'm somewhat biased but I think there's quite few proper uses for 3D-printers outside foundry industry. Very Happy Why spend huge amounts of money on metal printers when it's super easy to use plastic or wax prints as casting patterns.
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PostPosted: Thu Dec 29, 2016 8:20 am    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Thank you so much Jeff!

Two good coats of high build primer, followed by "chrome" spray paint(3coats) and some hand painted inset with flat black!
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PostPosted: Thu Dec 29, 2016 12:47 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Wow, that turned out nice Joe! Now I want one. Very Happy
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PostPosted: Thu Dec 29, 2016 1:13 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Looks great J I Joe. Thanks for sharing my friend. If Volks want one please PM me.
Enjoy.
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Solomon Grundy
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PostPosted: Thu Jan 05, 2017 11:07 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Next victim? Wink
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| |_______| '73 Thing "481"
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PostPosted: Mon Jan 09, 2017 10:11 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

I'll take one! That looks great painted. Pm me if they are still available.
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PostPosted: Wed Jan 18, 2017 9:30 am    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Here's something about mould making. I'd highly suggest the OP or anyone who has a printed part to do something similar (using silicone as the mould material and casting other resins into it).

I'm making a wax injection mould here, so one print can be replicated ad infinitum. Doesn't need much. A piece of plastic pipe, locating pins or some modeling compound (something like play-doh or similar) and some tape pictured here.
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Tooling material in this case is 1:1 mix ratio fast cast 2K polyurethane filled with aluminium powder. Polyurethane is a bad thermal conductor, so the aluminium is added to increase conductivity, reduce shrinkage etc.
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Mixing powders into the resin (part A in this case) will introduce lots of air into it, so one should give the filler mix some time to bubble air out or put it into a vacuum chamber if applicable. As this is will be a waxing mould, I only waited a couple of minutes and went ahead. Some air bubbles will float to the top in most cases but in this case it does not matter in any way. The final mixture here has a potlife of about 2-3 minutes-> better double check that everything is in order before adding hardener.
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Polyurethanes are exothermic and the mixture will reach a temperature way over the wax patterns melting point in a couple of minutes. Does not make a difference, in the end. Mixture is so viscous at that point and the molten wax has nowhere to go.
Image may have been reduced in size. Click image to view fullscreen.


First mould half is finished and flipped around after approx. 30min (demoulding time).
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Some mould release (silicone) is sprayed on the first half and all is ready to cast the other half. New mixture doesn't really stick on old, hardened material, but it will be a PITA to separate the halves if nothing is used.
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Here's the final product after removing the pattern. The mix fully cures in a few days and is machinable, so I'll drill injection ports etc. in a few days. Some trapped air bubbles in the first half, but those were filled in the other.
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The surface is already quite nice due to the accuracy of the particular 3D printer I used, but I think I'll use some fine sand paper to finish surfaces and remove any flash.
Image may have been reduced in size. Click image to view fullscreen.


If the same kind of process pictured above would be used with flexible silicone mould material, that mould could be used to cast polyurethane or other resins. Finishing one ABS print with acetone or sanding etc. and doing a mould would give one easy way to reproduce these. Painted resin casts will be also much more durable than a somewhat porous 3D print. But in the end, this is just something to think about Very Happy Everyone has freedom to do what they wish with their equipment and time.
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PostPosted: Fri Jan 20, 2017 10:22 am    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Welt, that is so cool. Glad you are having fun and sharing your experience with the group. I think that looks great! If time allows I may try that myself. Can't wait to see some of the first molds. Very Happy
Your 3D Systems printer is nice too, and I look forward to having another one of their systems in my labs at some point.
There have been some rumbling in management about a 3D metal printer at some point. I look forward to indulging that spectrum of technology as well.
Maybe I will use my CAD skills and make an emblem with a cool lattice structure in it. Wink

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Lattice structure
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"Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind."
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VW 181 Archive: https://sites.google.com/site/jeffgilleland/vw_archive
| _______
| |_______| '73 Thing "481"
| _\_\_|_/_/_
| |O||_4_||O|
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