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Old May 17, 2005, 03:08 AM
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California
Joined May 2005
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Went completely through the thread tonight. Very interesting content and lots of work especially by aerogel. I'm new to the thread and have interest in it continuing. I'm curious to hear if anyone has been able to achieve really sharp detail yet and has anyone tried pressure forming?

Gilley
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Old May 18, 2005, 02:31 AM
Registered User
California
Joined May 2005
30 Posts
Hi All,

Had time to try out a few experiments. Some success was achieved using a covering heat gun and a plastic oven cooking bag on 2 mm Depron.

The image below shows the equipment. The plastic funnel is for changing your motor oil but works as a small plenum and forming platform. Two molds are shown one male and one female. The process begins by rigging the foam on the female mold and covering the whole affair with the oven bag which is remains intact up to around 450 degrees Farhenheit (232 degrees Celsius). The shop vac is turned on and the heat applied till the foam droops slightly into the cavity. The female mold is removed and the male mold substituted with the foam situated on top and the oven bag surrounding the whole affair as before. The shop vac is again turned on and heat applied. You have to be careful around the front and rear sections to avoid the foam folding together in a crease. Pressing in on these areas with a gloved hand works well. A wooden clay modeling tool was used to increase the crease at the bottom. The female mold was again put in place and the nearly completed foam was placed into it before covering with the oven bag. The shop vac was turned on and heat applied to complete the finished canopy as seen in the second image. It sounds complicated but really isn't that hard to accomplish.

Some residual artifacts on the forward section can be seen. They are a result of the oven bag being bunched together while heat was applied. Keeping it smooth while forming is important even if you have to stop the vac and adjust the oven bag to get it smooth in the area being formed. Notice also that the foam was literally drawn into the mold not stretched which is interesting.

This came as a result of reviewing work on this forum and work done in Germany (they used cling wrap which triggered the oven bag idea). I was thinking of making a frame to hold the foam to disallow the ends creasing together. I guess that'll have to wait till tomorrow.

Gilley



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Old May 18, 2005, 06:57 AM
Thanks for the Fish!
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Land of cajuns
Joined Dec 2001
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That pretty much how a comercial machine does it...If you can get virgin depron and zepron...you will be set..

aerogel
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Old Oct 17, 2006, 04:16 PM
Micro Jet Pilot
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Joined Jul 2005
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Quote:
Originally Posted by aerogel
.....Unless you want to see it blow up.....

later aerogel

Hey,
I am pretty sure, if you add a layer of glass after putting the parts together you get a very sloid and light structure. If you already create such a nice fuse, you want it to last, right? Even if molding takes five minutes there is still a long way to make it fly nice. It will have to stand some crashes...

Chris
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