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material to easily form compound curves for car parts

material to easily form compound curves for car parts

material to easily form compound curves for car parts

(OP)
I am restoring/upgrading an old car and I want to make some 3D interior door panels (DP),  glove box (GB)inserts (originally card stock) and replicate an optional exterior windshield sunvisor. I'm looking for a material I can form easily that has sufficient inherent strength to handle wind (latter case) or abuse.  The door panels could be vacuum formedas they have a perimeter in a single plane. The GB inserts are squashed ovals w/ a flat back, 9 inches deep.  The visor is convex curves in width and X section.
Fiberglass cloth & resin comes to mind for the GB & visor, but what materials can I make easy & cheap moulds from?
The DP is irregulay polygon perimeter which I want to make 3D in the shape of a round or oval speaker, with the varying hyperbolic curves that would occur if a stretch material was pulled over the speaker.  How could I do that with a fabric that would "set".  Thermoplastic and vaccum would give the correct shape.  Anyone know what to sie for the perimiter frame and heat source?  Would ABS sheet "stretch" 3 or 4 inches?  Stretch fabric (?) and some spray-applied cataylized material (?) that wouldn't cause sags? krcaddis@thegrid.net  PS the car is a '61 Morris Minor Pickup

RE: material to easily form compound curves for car parts

The last time I had an orthopedic cast made, the structural material was an open-weave fabric tape that was catalyzed by application of water.

The wetted tape stuck to itself readily, so required some care in application.

It had a noticeable exotherm and it became rigid in maybe ten minutes.

---

To answer your question, yes ABS sheet can be drawn 3 or 4 inches, but doing so requires more patience or more controlled automation than is easily mustered in a nondedicated shop.

 

Mike Halloran
Pembroke Pines, FL, USA

RE: material to easily form compound curves for car parts

materials used for forming orthopedic temporary restraints fall under such names as:
surlyn, vivak kydex and others are availabel thru AIN Plastics/ thyssenKrupp  materials and services

they appear to be suitable for your application

RE: material to easily form compound curves for car parts

I would look at the product (Dynamold Shim) from Dynamold to see if they are applicable.

http://www.dynamold.com/shim.htm
 

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