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Old Sep 12, 2010, 06:01 PM
ken_nj is offline
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DIY - Vacuum forming

Have I have few things I need to make for my 1/24 scale boat that I have not been able to find online. Besides learning something, I also probably saved some money making them myself. The pictures should tell most of it. These first items I show here are floodlights that will getting super bright LED's. I started out with .010 plastic cut to 6"x6". Changed to .015 as it sturdier. It was trial and error for a while to correct two issues. One was webbing, the second was bubbles at the bottom of the pattern.

Other parts I will be making are trash cans and coolers. Not sure what else there will be.
Last edited by ken_nj; Jan 02, 2011 at 11:20 AM.
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Old Sep 12, 2010, 06:23 PM
freechip is offline
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Surface, Air & Water Rc Toys..
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Wow, nice work.
Old Sep 12, 2010, 06:53 PM
Kmot is online now
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Grumpa Tom
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Old Sep 12, 2010, 07:17 PM
green-boat is offline
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Boats on the brain!!
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1:24 scale....

I'll be your official tester.
Old Sep 12, 2010, 07:23 PM
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made of fire and pop rocks
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Old Sep 12, 2010, 08:03 PM
ken_nj is offline
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Thanks guys! Here are 2 quick video's in action.

Vacuum forming, part I (0 min 19 sec)

Vacuum forming, part II (0 min 29 sec)
Last edited by ken_nj; Oct 19, 2013 at 09:47 AM.
Old Sep 12, 2010, 10:25 PM
MILLERTIME is offline
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Taking care of the pond.
What they all said.
Old Sep 13, 2010, 12:14 AM
green-boat is offline
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Boats on the brain!!
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Twist the frame and pop them out like ice cubes.
Old Sep 13, 2010, 01:09 AM
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Trick I have used to fix the frames is when they get too loose wrap a layer of masking tape around the tongues of the corners (I have the same frames in my windows and the dogs go through them so I am an expert at replacing screens). I that does work you can take a nail and dent the frames into the corners slightly.
Last edited by fooman2008; Sep 13, 2010 at 01:10 AM. Reason: spellcheck!
Old Sep 13, 2010, 06:26 AM
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A great thread with some neat thinking

Well this is a definate copy for future review and file away into the technique folder

Great Job,
Old Sep 13, 2010, 02:18 PM
GILL RC is offline
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Nice job.
Old Sep 13, 2010, 02:22 PM
ironman1 is offline
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The Sicilian Texan
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ken nj, that is a super cool box. I am getting materials together now to build it. ironman1 (Ray)
Old Sep 13, 2010, 04:12 PM
ken_nj is offline
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Building the box is simple. Cutting, assembly and gluing should take about 1-2 hours. The plywood frame has glued rabbit joints. The cross braces float in the 2 sides and the 4 dowels float in the cross braces. My MDF top (platen) and bottom right now have a tight fit into the rabbit joints so there is minimal air leakage. The top or bottom can be glued\siliconed or you can use masking tape to seal the joints. I suggest gluing\silicone the bottom and leave the top removable. This will allow you to have platens with different hole patterns.

If you can get the woven metal window screen, you really do not need all of those little holes. Just drill one large hole, maybe 1 to 1.5 inches in the center. When you place the screen over this large hole, the screen will allow the vacuum to distribute evenly under your pattern. Two layers of screen might be better.

If anyone needs any other info, just ask away.

For the window screen frames, some hardware stores might have metal corner braces, you might have to miter the corners. They would be better as the plastic, after repetitive use will deform due to the heat. You can do as Foo says, dent the frame to hold. Or build some sort of wood frame.

When you sandwich the frame with the plastic in the oven. Elevate the frame with two pieces of wood as the plastic will sag and you do not want it touching anything as it warms up.
Last edited by ken_nj; Sep 13, 2010 at 04:32 PM.
Old Sep 14, 2010, 01:54 AM
desron48 is offline
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thanks ken........gunna start constructing mine this weekend.....joe
Old Sep 14, 2010, 02:11 PM
der kapitan is offline
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"day ain't over yet-"
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I pulled instructions for a vacform box similar to yours from the internet a few years ago, but never built one.

Yours appears to be simpler to build, and may be a better design.

Now where did I put that---.

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