Your input on how to fabricate these parts --- is by hand possible?

[verticalflight]

We are working on a 1973 modernized Porsche build.

Basically, we want:
-- left/right custom lens housings for the front of this car
-- left/right custom lens housings for the rear of this car

These 4 parts will be finished in brushed aluminum and connect to the internal housing pieces that mount to the car.

CNC shop wants $4k to make these parts, but that doesn't include doing the 3d scanning and modelling work to create the models.

We have already prepared a clay molding of the desired parts. We also have a shop ready to go to make the acrylic lenses (using clay molds - not 3d modelling).

Attached are pictures of everything!

Is it possible to make these cost effectively by hand? Any suggestions on how to do it?

http://imgur.com/a/LmZjT

[68Cuda440]

3D rapid prototyping is a lot cheaper than CNC. Example: https://www.youtube.com/watch?v=OzIGfcIyBnc

[DreamRyder1963]

Crafty B makes some similar products. I believe he uses molds to do it.

http://crafty-b.com/

[jlcustomz]

I have shaped acrylic by heating in home oven & then hurrying up & pulling around or between wood or metal forms. Trying to have a factory like inner deflector texture would be another story though. But you are doing a modernized custom , so you have options. Looked into making custom inner diffuser assembly between lens & led assembly before. Also sampled some transparent [duplicolor] red paint on the inside of clear plastic for tail lens. Looked pretty good from outside & sample has held out for 2 years being tossed around the shop.

Just a few thoughts. Ever come up with a plan direction for custom bumpers?

[minendrews68]

What about finding someone that can 3D print the molds?

[rchaskin]

I would check with Ring Brothers or Greening Auto.

They might could help you out.

[verticalflight]

Just to clarify, we only need the metal rim parts machined out -- not the existing innards of the light housing (that can probably be modified from the existing part). Also we don't need help with the lenses, we have sourced a provider for that.

And we need the exposed metal trim finished in brushed aluminum, so not sure a plastic printed part would work.

So any other ideas? Thanks!!!

[jlcustomz]

If 1/8" thick aluminum would work, it could be cut out with various hand power tools & bent to shape , then sanded to a brushed finish. Aluminum tabs or rods could be tig welded to backside for attachment

Other thought would be hammer forming which would require much more skill. would have to make forms from at least a hard wood to bend the metal over after annealing it with a torch to soften it.
Could even be done with stainless sheet, which will brush nicely .
Aluminum will cut with many of the same carbide tipped tools as with woodworking .

With the shape of the front parts, I could see where making that from a big enough solid chunk of metal would be cost prohibitive.

[verticalflight]

Ok so we made the housings by hand out of aluminum. Looking good so far.

Now we need custom lenses

Who can make clay molds out of the inner parts of the housings, then create an acylic mold for the lenses (with color - amber front, red rear).

It is important that they aren't just clear lenses, but have a pattern (either via mold or carved in) on the inside for light diffraction.

Anyone?

Best,
Kris

[jlcustomz]

Trim is looking good. thought you had a source for the lenses . Don't know of a source to make factory like textured inner sides

I know tinted plasticsheets are available. An inner diffuser layer, such as used for fluorescent lighting is an option. There are better looking versions than what you see at a homestore.

Also , another thought would be to go the modern approach & make the innards decorative & use led & hid lighting. For example up front, look at the new 2016 Camaro ss headlight. Looks like a thrust bearing pattern around the HID projector & looks like an industrial gear on the side of it. Just another option to consider which would make the project stand out in small details if done correctly.

[verticalflight]

We had a source for lenses but they fell apart... ok will research your ideas, thanks.....