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Topic Review (Newest First)
06-11-2019 08:42 AM
jseabolt Scroll to 9:57. This is where the production of the panels begins. The orange powder the women is shoveling is the resin material. At 14:43, this is where they start pressing the body panels. Then the video jumps to something engine production. At around 24 minutes the video resumes the body panel pressing. The panels come out an orange color then are trimmed on a bandsaw!

06-11-2019 08:26 AM
cerial I have been collecting trampoline fabric(polypropylene) for a number of years. The stuff is uv resistant, wicks away water/debries, and can be found very cheap used. I have this fun idea of stretching it over a ultralight space frame here eventually.

But the idea of "shaping" the fabric it by heating/shrinking into a relative shape by sandwiching it between a upper and lower mold then heating those molds has also crossed my mind.

I am experimenting stretching the fabric over fenders and hood of a square body in April. Many things are put on hold until I am in a larger place with less "restrictions" on my hot rodding activities.

Fiberglass is fun. But most people don't realize just how heavy reliable fiberglass panels end up being.

If you could "shape" trampoline fabric (polypropylene) into a rigid structure you have potential for not only a lightweight highly uv resistant panel you could do it cheap and quickly. Less cure time, sanding, and no need for paint.

As far as mashing/melting. There is potential for casting or meshing into a shape. But I would be concerned with how the chemicals would react and the potential for cracks in a large structure such as a fender. One of those things where "printing" items(or using a compatible fabric) may yield a mesh structure for you to lay your mash upon.

That being said. Keep experimenting. If the stuff is cheap and your enjoying it you will have fun in learning. Just take proper precautions as burns do happen and your dealing with some stuff you should not be directly breathing in.
06-11-2019 04:33 AM
jseabolt Here's the speaker boxes I was talking about.

More photos:

I find these "old school" surface mount speaker boxes from the 1970s from charity stores all the time when I find them.

But I couldn't find the correct size to go on the kick panels on my Trabant so I made some that would fit the car. I used some 3M adhesive tape on the backside instead of screwing them into the panels.

It's a multi-step process. I cut the boxes out to the size I wanted, tapped the outside to hold them in place, brushed resin on the inside, allowed this to cure, pulled the tape off and applied some polyester strips over the gaps on the inside and out and more resin. Then covered them with felt.
06-10-2019 06:30 PM
Rip VW Airplanes have been covered in cotton fabric, and Polyester.

The using of a cotton bed sheet should work exactly the way you want it. Cover the fabric with fiberglass resin. If you need more strength try an another bed sheet!
06-10-2019 02:55 PM
39 master Some of the late model parts that look like plastic are actually nylon 66. Nothing will stick to it but it can be melted to fuse together and then sanded. I did this with an LS truck intake and it came out looking good.
06-10-2019 01:57 PM
jseabolt I've been thinking about experimenting making a fiberglass hood out of an old bed sheet instead of polyester for my riding mower. Just to see how well it holds up.

I've used felt and even cardboard material in the past as a binding agent instead of polyester. I've made speaker boxes out of cardboard brushed with fiberglass resin.

My Trabant uses a material called Duraplast which is a form of fiberglass where the binding material is cotton and wool which looks like the same stuff that comes out of a dryer lint trap.
06-05-2019 07:03 PM
cerial I have been getting parts around for a couple years now to build a electric cj5 out of hdpe.

Bolt, panel bond it together, then paint the exterior. Brace it correctly and incorporate a cage into the frame to make a mono "space" frame. It wont be light. But lighter then a steel body with "armor" bolted on.
06-05-2019 06:01 PM
Making car parts from trash (plastic)

You may have seen YouTube videos of people melting down #1 plastic (milk jugs) into plastic blocks and making stuff out of them.

I found #1 plastic way too time consuming and didn't get the results I was wanting so I decided to try a #5 plastic material instead which is called Polypropylene, commonly use in Tupperware, yogurt tubs, (orange) medicine containers, and plastic caps of soda bottles.

A few years ago I removed the plastic body kit (ABS?) off my 98 Chevy conversion van that was falling apart. The factory removed the lower air dam or valance so I was left with these ugly front bumper brackets.

I tried to find this piece with some difficulty because the van is so old but once I found the GM part number, all I found there three "pickup only" auctions on Ebay for $70 a piece.

So I decided to use a piece of landscape edging as an air dam which I think looks better than the factory piece. Initially I cut some blocks out of oak which bolts to the bottom of the bumper and used HELP! nylon plugs to secure the edging to the blocks. Over a course of time the wood shrank and the bolts required constantly tightening.

Ideally you could use metal L brackets if you wanted to.

At work we run these rolls of wood pulp and they have these #5 plastic core plugs to prevent the center of the rolls from collapsing during shipment and handling.

Like most plastics, the trick is to heat these in an oven at 350 F to melt them into liquid form. This took 18 plugs over a course of 6 hours. Lay 6 in the pan, melt and repeat until a cake is formed. Of course you wouldn't want to do this inside or use the oven in your house since this stuff gives off noxious fumes.

Once the cake cools it can be cut with a hacksaw or bandsaw (what I used) into blocks. I cut these into 3 X 1 X 1 inch blocks. These bolt to the bottom of the bumper on my van and then I used some of those interior screws to hold the landscape edging to the blocks.

One problem using this material is it's somewhat brittle when trying to clamp it down or drilling through it. That's one reason I used screws this time instead of the nylon plugs for fear knocking them in may break the plastic.

When I started to cut into the cake, I found some air bubbles and what appeared to be superficial cracks. Probably from where the plastic melted against one another.

If I decide to use this material again for something, I'm going to try to break it up into small pieces (like putting it in a bag and hitting them with a hammer). Or possibly finding an old blender and cutting them up into fine pieces.

I wonder what other possibilities I could use this type of plastic to make stuff out of.

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