Vacuum Forming ABS, acrylic, and PC

[Meursault]

I guess this would be my first post after lurking here for some time. I'm looking at making a DIY setup for recreating bodypanels, and making a custom tail section. I'm going to be using ABS for the body panels, and then Acrylic to make a new tail light, and considering all the other options, this seems to be the most cost effective versus trying other methods with which I have no experience.

I was curious if anyone else had some experience doing this, or had any suggestions. At first I wanted to used PC to make the body panels just so I could rattle can the underside, but still acheive a beautiful, scratch resistant glossy finish. I'm reluctant to do this because I'm unaware of how PC will fair with sunlight and the heat.

[JokerZwild]

Welcome to the post side of things! Sounds pretty interesting. Id luv to see a few pics of your set up once you work the details out.

[Meursault]

I'm going to make a fighter out of it. Just going to take off headlight/cluster, and make a bracket out of a spare triple cap I have for dual headlights and an Acewell gauge, and make an abs bracket for the gauge and dummy lights. I'm going to remake the rear side panels, so they flow better without the front fairings, and curve into the new tail light better.

[Shipster]

Welcome to KR, and good luck with the project!

[Kreylyn]

I guess this would be my first post after lurking here for some time. I'm looking at making a DIY setup for recreating bodypanels, and making a custom tail section. I'm going to be using ABS for the body panels, and then Acrylic to make a new tail light, and considering all the other options, this seems to be the most cost effective versus trying other methods with which I have no experience.

I was curious if anyone else had some experience doing this, or had any suggestions. At first I wanted to used PC to make the body panels just so I could rattle can the underside, but still acheive a beautiful, scratch resistant glossy finish. I'm reluctant to do this because I'm unaware of how PC will fair with sunlight and the heat.

Check out this site for some great do it yourself tools for that project.

http://www.instructables.com/

ABS is not hard to vacuum form for general curving shapes. It may take a high powered vaccum to get sharp curves if your needing them for the thicker pieces.

For lenses, there are a couple of options. If you want to re-create a piece your better off getting the ingrediants to mix up, and pour into a mold, to get that pro look. If your starting from scratch, you can start off with a piece of refractive lighting cover you can pick up at lowes. These are in the lighting isle... If you are inside an office, look up.. it's what covers the floresent lights most of the time.

Good luck!

Krey

[HexKrak]

Here's some resources for ya:
One of the most popular DIY vacuum forming setups, and www.tk560.com is a forum much like this one, only dedicated to vacuum forming and fabrication.

http://www.tk560.com/vactable4.html

another similar diy vacuum forming machine on instructables

http://www.instructables.com/id/Vacuum-Former/

An FAQ on diy vacuum forming stuff

http://www.tk560.com/phpBB2/viewtopic.php?t=652

I get my ABS locally from a plastics distributor but the minimum order is $100, but they did do my cutting for me, which saved me a lot of time and effort.

[JokerZwild]

neat stuff!

[airforceranger49]

definately go with vacuum forming.. its actually really easy once you do it a few times... and you can make all kinds of custom shapes with it

[Sounder600]

I was a lurker for a long time too -- Welcome to the posting side of things.

Good luck with the fighter project, I love fighter bikes.