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carolina
recumbent guru

USA
594 Posts

Posted - 09/21/2017 :  16:47:19  Show Profile  Visit carolina's Homepage  Reply with Quote
My oven is like this: 4x4 , 32" tall inside. Can do many of my molds for curing better and make some windows.



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velosRus.com

Edited by - carolina on 12/03/2017 16:41:44

warren
human power expert

USA
6117 Posts

Posted - 09/22/2017 :  08:37:06  Show Profile  Visit warren's Homepage  Reply with Quote
Looks good! Garrie has been using radiant heat with good results. His method works without need for an oven.
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carolina
recumbent guru

USA
594 Posts

Posted - 09/22/2017 :  15:49:30  Show Profile  Visit carolina's Homepage  Reply with Quote
Well, this is a good thread. Some vacuum mold, some can not. A lil' more interesting. Maybe garrie will give some tips snd pics.

Questions:
Which one would lay down in a female mold and drape form easier??? Look a my cf canopy, i can't vaccum. I use cf canopy mold as windows mold.

Cell cast acrylic is 69$ if in stock.
Polycarbonate is $60, iam gonna drive up and get a sheet. (4x6') much in stock @ 1/16" thick.

Do you know the optics of cell-cast vs polycarbonate???
_____________________
My oven is also multitasking to cure my parts too at about 140 degrees.



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Edited by - carolina on 09/22/2017 15:51:22
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Garrie L Hill
human power supergeek

USA
1692 Posts

Posted - 09/22/2017 :  20:10:41  Show Profile  Reply with Quote
OK, here is a video showing how I made the "lens" for the rear tail light of Rick Wianecki's velomobile

https://vimeo.com/18730038

Scroll down on the next page to read how Rick installed the lens.
http://www.recumbents.com/wisil/wianecki/velomobile/page8.htm


Here is the page showing the forming of a large teardrop canopy for a Varna streamliner

http://www.recumbents.com/wisil/geebee/geebeevarna.htm


Garrie "carbon based lifeform" Hill
HPRA Co-Dictator of the East
for pics of some of my time and money sucking projects
http://s58.photobucket.com/albums/g277/cfbb/
and videos
http://vimeo.com/5513519


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carolina
recumbent guru

USA
594 Posts

Posted - 09/22/2017 :  22:04:21  Show Profile  Visit carolina's Homepage  Reply with Quote
This is the way i will try except " I USE FEMALE MOLD" to hopefully find an optical seat down in mold for front windshield.

https://youtu.be/VlzfPzQXACY

Blue felt to lay on mold/tool. I have second orange mold press part made like in vid.

Todd's canopies of ft. Laud fla. was a good friend,,,, here last summer to teach me a few things. Unfortunately he was killed in his plane bout 7 months ago. He basically said kiss! He was 325 degrees for 10 mins.

I noticed this guy uses 145 degrees for 25 mins. The poly or acrylic is layed on 100% piece of cotton. U see him straightening it out with metal tube in video.

What you could help me with is trimming!!!
_________________

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Edited by - carolina on 09/24/2017 14:02:36
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carolina
recumbent guru

USA
594 Posts

Posted - 09/24/2017 :  13:50:51  Show Profile  Visit carolina's Homepage  Reply with Quote
Oven =$& better cured parts & windows:

My oven going together, rays gonna wire it for me. Found kiln filler in caulk tube on ebay to do inside joints. It was 18$.



Top on now, 4 by 4' oven. Door over 3" thick, plug door, with 2 handles, no hinge.



Found 1 roll of tape: lil' high but l need it.


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Edited by - carolina on 12/03/2017 16:41:03
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warren
human power expert

USA
6117 Posts

Posted - 09/26/2017 :  21:05:10  Show Profile  Visit warren's Homepage  Reply with Quote
At least shipping is free...

Edited by - warren on 09/26/2017 21:06:01
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Grant-53
recumbent guru

USA
544 Posts

Posted - 09/26/2017 :  21:52:16  Show Profile  Reply with Quote
Does it really need to be MIL STD? ;)
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Garrie L Hill
human power supergeek

USA
1692 Posts

Posted - 09/27/2017 :  05:13:31  Show Profile  Reply with Quote
MIL spec is so passι! AS 9000 or NADCAP.

Garrie "carbon based lifeform" Hill
HPRA Co-Dictator of the East
for pics of some of my time and money sucking projects
http://s58.photobucket.com/albums/g277/cfbb/
and videos
http://vimeo.com/5513519


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carolina
recumbent guru

USA
594 Posts

Posted - 09/27/2017 :  17:40:15  Show Profile  Visit carolina's Homepage  Reply with Quote
Caulking for a kiln came in, ebay 18$. Will shoot on seams inside first then more aluminum foil. 8 year record rip-off someone sold on ebay.

DO NOT BUY

DO NOT BUY

DO NOT BUY THIS STUFF



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Edited by - carolina on 12/03/2017 16:39:44
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carolina
recumbent guru

USA
594 Posts

Posted - 10/07/2017 :  12:04:11  Show Profile  Visit carolina's Homepage  Reply with Quote
Out side finished & door w/2 handles. Few weeks inside now.

[/URL]

Door is push in 3&1/2" thick.
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carolina
recumbent guru

USA
594 Posts

Posted - 11/29/2017 :  16:32:44  Show Profile  Visit carolina's Homepage  Reply with Quote
Trying acrylic “ cell casted “ first. Maybe later polycarbonate. Drove hour to get 4x6 foot sheet/$84 out the door. Two pieces 36x36” cut for me and the left-overs to practice with. I will show my practice pieces in a few days.



Working on ceiling up in oven, i can set in it. Two dropped aluminum ceiling’s in it then the heat element hanging below that on ceramic washers. 320 f degrees for 10 mins. Acrylic lays on piece of 100% cotton that covers the whole floor.


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Edited by - carolina on 12/03/2017 16:36:17
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warren
human power expert

USA
6117 Posts

Posted - 11/30/2017 :  08:12:44  Show Profile  Visit warren's Homepage  Reply with Quote
Note that acrylic shatters like glass, so it's not recommend for use in HPV applications.
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carolina
recumbent guru

USA
594 Posts

Posted - 11/30/2017 :  10:16:12  Show Profile  Visit carolina's Homepage  Reply with Quote
Yes thanks, but i will be experimenting for a while. CCA is easy to hold heat longer. Poly cooling is really quick. These are pressed in two part mold/male and female.

velosRus.com
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Speedbiker
human power expert

USA
3755 Posts

Posted - 11/30/2017 :  10:43:40  Show Profile  Reply with Quote
Before I knew better I had Fox/Aircraft Plastics blow me a canopy. They used precision fast acrylic and a template from a F-1 race plane. While it would crack at every chance, and would be dangerous in a crash, but man was that thing BEAUTIFUL! Crystal clear and very low distortion.
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carolina
recumbent guru

USA
594 Posts

Posted - 11/30/2017 :  16:05:36  Show Profile  Visit carolina's Homepage  Reply with Quote
Windows:

Well, SB will get poly next trip to piedmont plastics but working on my cut techniques and heat transfers.

Oven:
Making homemade ceramic washers for oven from free floor tiles and drill bit from lowes. [update] buy the lennox diamond ceramic drill bits only/$14.50.






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velosRus.com

Edited by - carolina on 12/01/2017 17:45:58
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carolina
recumbent guru

USA
594 Posts

Posted - 12/03/2017 :  15:25:08  Show Profile  Visit carolina's Homepage  Reply with Quote
1)Video again (below) has great technique but i use female mold instead of male mold.
2) my small test scrap mold for learning curve.
3) ya have to learn how first. Gotta start somewhere.
4) Speedbiker if l can do this with poly and be able to see thru it. Yay!



[Watch]
https://youtu.be/VlzfPzQXACY
__________________

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Edited by - carolina on 12/03/2017 16:35:16
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warren
human power expert

USA
6117 Posts

Posted - 12/04/2017 :  11:01:51  Show Profile  Visit warren's Homepage  Reply with Quote
PETG is the best option I found. It is inexpensive, melts at low temperature, forms well, and it optically clear. It is reasonably fracture resistant and does not shatter. Like most plastics, it will discolor or gt brittle if left in the sun. I have personal experience with blown PETG bubbles that are close to 20 years old and are still being used.
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harv
recumbent enthusiast

389 Posts

Posted - 12/04/2017 :  12:36:35  Show Profile  Reply with Quote
UV resistant PETG sheet is available. A tip: to help prevent scratches when handling AND vac forming petg, leave the blue cling film on and remove it after the vacform/trim operation.
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carolina
recumbent guru

USA
594 Posts

Posted - 12/04/2017 :  15:47:56  Show Profile  Visit carolina's Homepage  Reply with Quote
Yea, will get some poly next run. Never any vaccum forming here. I will try video above or use solution B as wrote above. Oven was built to cure part too. I am making part B or starting on that plug next week. I can use all 3 situations with the oven.

Ill check for UV harv, thanks. Piedmont plastics is a average supplier.

velosRus.com

Edited by - carolina on 12/04/2017 15:49:18
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Speedbiker
human power expert

USA
3755 Posts

Posted - 12/04/2017 :  19:51:25  Show Profile  Reply with Quote
Excellent video Mike.
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carolina
recumbent guru

USA
594 Posts

Posted - 12/06/2017 :  12:32:09  Show Profile  Visit carolina's Homepage  Reply with Quote
Learning curve mini mold l made. Both pieces covered in felt.







1) 320 for 10 mins. 1/16th inch thick.
2) was simple.
3) cools in minutes.
4) layed acrylic on pizza stone, parchment paper, then 100% cotton piece (t-shirt material) in oven
5) textbook except for the felt impression left on acrylic.

My next hurdle is the felt left imprint on the lil mini piece. What to do next?? Maybe cotton??, or just the clean plain molds.
————————

Took felt off of the lil’ molds. Start over with some new ideas.

velosRus.com

Edited by - carolina on 12/06/2017 14:36:56
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carolina
recumbent guru

USA
594 Posts

Posted - 12/06/2017 :  16:05:45  Show Profile  Visit carolina's Homepage  Reply with Quote
Much better without felt,, but not good enough: hunt more info. My buddy who could have helped me was killed in his plane months ago.


______________
This is the way l cut all plastics now:

https://youtu.be/XPlbZdwQ2AM

Another molding of acrylic:

https://youtu.be/pgtwAPWraZE
_______________
velosRus.com

Edited by - carolina on 12/07/2017 11:58:10
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carolina
recumbent guru

USA
594 Posts

Posted - 12/07/2017 :  11:03:19  Show Profile  Visit carolina's Homepage  Reply with Quote
Harv, gonna try leaving film on next one like you said. Tried 3 will felt and cotton based mold. Cotton best. Will post later today.

velosRus.com
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carolina
recumbent guru

USA
594 Posts

Posted - 12/07/2017 :  13:48:52  Show Profile  Visit carolina's Homepage  Reply with Quote
Harv, your version is best, just tried another. I might b able to do it correctly with your idea because the real mold for frt windshield is not compound at all compaired to this lil 10” sample mold i made. And its possible the polycarbonate will do a better job along with your idea of leaving the film on. Thanks. Every tip helps. This molding is very secretive. Will get some polycarbonate soon.

velosRus.com
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harv
recumbent enthusiast

389 Posts

Posted - 12/07/2017 :  14:27:54  Show Profile  Reply with Quote
You have to dry polycarbonate ie 375f for 24 hours in an air circulating over. It's hygroscopic and will release entrained moisture as steam bubbles in the part. IIRC PC has a forming temp 450-500deg and would probably melt any poly cling film.

I think aircraft canopy fabricators would use greased felt covered molds for forming acrylic. The grease (crisco?) is softer than the hot acrylic and traps debris before it can leave a mark in the hot plastic.
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