Vacuum Forming Attex Nose Pieces

[evil8x8]

The talk about reproducing Attex bodies got me interested in Vacuum Forming. So I thought I'd give Vacuum Forming a try for fun. I thought it would be cool to vacuum form an Attex Nose Piece. I built my vacuum former out a scrap wood. It is similar to the one in this video. (

) I sealed all of the joints with caulking and tape. I also set it up to use 2 shop vacs (one on each end). The size plastic needed to make the nose piece was too big to fit in my oven so I came up with another plan. I decided to use an electric hot plate and with much trial and error, I ended up using 2 hot plates with the thermostats disconnected and a piece of sheet metal to ensure even heat. I put the hot plates it the box that the plastic is stapled to. Before I buy the proper plastic, I tested it out with some plastic from an old boot tray. It wasn't the best plastic I could have used, and I think it was too thick but I didn't turn out too bad for my first attempt. Now that I know my Vacuum Former works, I am going to buy some High Impact Polystyrene. I should be able to get some fairly cheap. Anyone know of a good place to get some? I think with some better plastic and some more practice, I could make a Nose Piece identical to the original.

[lewis]

Keep trying Cole. You have a good start.

[jerseybigfoot]

Cole! Excellent job. you may want to make a plug of the original with plaster or other pourable quick hardening plastic. You may end up with more detail that can be formed in. You can experiment with a plug from the front or back of the original. Not sure what the shrinkage rate will be. A plug from the front may give you the best replication. if you are not getting detail into the grill slots you may have to make some small holes in the plug that are subject to the vacuum. Keep up the good work. Most teenagers goof off during the summer but not you. I'm sure you dad is very proud.

[Amphiman1]

vacumme form.

Excellant!!!! keep a goin' !!

[George]

Very cool Cole. I'm interested in what you end up with. Put me on the list of potential customers.

[evil8x8]

Cole! Excellent job. you may want to make a plug of the original with plaster or other pourable quick hardening plastic. You may end up with more detail that can be formed in. You can experiment with a plug from the front or back of the original. Not sure what the shrinkage rate will be. A plug from the front may give you the best replication. if you are not getting detail into the grill slots you may have to make some small holes in the plug that are subject to the vacuum. Keep up the good work. Most teenagers goof off during the summer but not you. I'm sure you dad is very proud.

Thanks for the ideas!!! I might have to do that.

I was hoping that with a thinner plastic, it would be easier to work with when heated, and I could just push the slots in by hand if needed. I was also thinking of forming a grill and cutting out the slots and use it as my die/mold.

Does anyone know of a good source of plastic sheets? Preferably polystyrene. I am trying to find a place local so I don't have to pay shipping(the shipping costs more than the plastic).

[evil8x8]

I just realized that the chief style grill is the most complex and probably hardest to duplicate. The others styles should be easier to get right.

[jpswift1]

Great work, Cole! You're really making big progress there.

I think you're absolutely right, the Chief grille is the hardest to form because of all of those bumps and ridges. I know there are some members out there (including myself) that were missing their green poly front grille. I used a Chief grille that I traded from Don instead because I thought I would never find a poly green grille. Maybe now because of your excellent ingenuity a green poly grille would be something available in the near future.

[LarryW]

Good Work!!

Thats pretty cool. I was thinking, what if you could seal off the top and pressurize it with compressed air, while vacuuming bottom. Maybe a plate with an air fitting on it that you just set on the top real quick and hold it down It would be something I would try, but not everything I try always works.

[evil8x8]

Great work, Cole! You're really making big progress there.

I think you're absolutely right, the Chief grille is the hardest to form because of all of those bumps and ridges. I know there are some members out there (including myself) that were missing their green poly front grille. I used a Chief grille that I traded from Don instead because I thought I would never find a poly green grille. Maybe now because of your excellent ingenuity a green poly grille would be something available in the near future.

When I buy some plastic, I try to get some yellow and green too. If someone could lend me a poly style grill to use as a die, I don't think it would be too hard to make one.

Thats pretty cool. I was thinking, what if you could seal off the top and pressurize it with compressed air, while vacuuming bottom. Maybe a plate with an air fitting on it that you just set on the top real quick and hold it down It would be something I would try, but not everything I try always works.

Thats a great idea!!!

[hdble]

Cole, try McMaster-Carr.com. We have purchased all types of plastics from them in the past. I don't know if they will have sheets big anough, if not try Laird Plastics, both are on the web. Both are industrial supply.

Looking good so far.