22 replies to this topic

[olds_kool_lews]

right, here goes... i have a clubman estate, but no where does clubman estate shells for rc minis, however, last night i bought myself one of those abc mini traveller shells off ebay, i plan to fill this with plaster of paris, or even body filler to make an exact copy of it, then add to the front more filler etc and profile it to look like a clubman estate, being filler/plaster of paris, it should be pretty easy to do, my question is when it comes to making a plastic copy shell of the new shape, what plastic am i better off using? 1 for the details, and 2 so it can be painted inside and gives the desired look or nice shiney paint, i have been looking at lexan, is there anything else out there that would be suitable?

i will also be making my own vacuum former to form the shells will post a project page when i get up and running!

cheers

Edited by olds_kool_lews, 06 August 2010 - 07:25 AM.

[bunch1980]

Sounds like a plan, I would use Lexan (polycarbonate) as thats what most rc bodies are made from. I think most important bit for details depends how good your vac forming machine is, so it sucks it tight around all your details etc. I remember using one in school for similar and it was so weedy lol

[Stevee]

yeah vac forming would work

and couldn't you use fiber glass ;]

[davidv]

Have a go using Body Filler to re-shape. Easier to detail.Will be an interesting project.Hope you can sell a few afterwards.

[Spud133]

Make sure your shell which you are hoping to replicate is extremely strong as when they are being formed the forces pulling down may criple the shell. Another thing with vac forming a shell is to make sure that it is perfect as it will expose any little defects.

[camp freddy]

I have a 1/8 scale buggy (hyper 7) and was looking at making a mini shell for that, I was thinking
of using some modellling foam they use for pattern making..

Edited by camp freddy, 07 August 2010 - 03:49 PM.

[olds_kool_lews]

the shell that i'll be using to form my new shells will be a solid plaster cast of the original abc countryman shell, with added chicken wire inside to reinforce it, and sculpted body filler on the front end to make it into a clubby estate. so should widthstand the pressure from the vacuum forming.

the abc shell arrived today, so gonna go out in a minute to pick up some plaster of paris and make my cast (i could also make a fruit jelly in the shape of a mini if i wanted! lol)

hopefully can start making the front end by the end of the day! ill post some pics up later of how i get on!

[olds_kool_lews]

well the abc countryman shell arrived this morning, so a trip to hobby craft to pick up 4kgs of plaster of paris was on the cards, with all the vitals collected, heres the progress i made today, i just have to let the plaster full harden before i attempt to remodel it into a clubman estate shell....





so far so good! should be mocking the chassis up for it soon, im going to build my own rc car, will be a good trial to see how it fits/what will need modifying in the moulding process to make it easier etc

[DaveVader]

Ahh dude, that's wicked!
So detailed!
I'll bring my camera tomorrow, get some pictures too.

[danie garry]

looking good, should make a bit of extra dosh if u'r the only 1 making clubby estate shells! good luck with it

[olds_kool_lews]

thats what im thinkin, no one else makes clubman estate shells, or even good clubman saloon shells other than those that fit mardave minis, and even them are poor quality, and thick abs plastic! ive emailed several vacuum forming companies in my local area to see if they will be willing to help me out and make a dozen or so clubby estate shells so i can perfect the cast/mould etc, then if all goes well, ill go into mass production and sell them!

im going to wait a week before i start sculpting the shell, to let it dry out completely, then i can add the body filler etc and not fear it falling off etc

but if i really want to go to town, i may start producing a complete rolling chassis to compliment the estate shell, which can be fitted with either nitro engine or electric motor, but we will see how the 1st one goes and how much it costs to put together

[nomis]

I have plenty of vaccum forming know how - i worked in a company that had a automatic one for 13 years.

We used to mould the glove boxes used on the late mini dashes for Rover!!.

I would say polycarb be the best for the job, we did some trials for mardave and another Rc company years a go - one was a beetle.

Think it was 3mm we used. You will have some shrinking during the process.

If you need any help PM, im just down the road @ Brackley too.

Simon.

Edited by nomis, 07 August 2010 - 07:31 PM.

[Tupers]

Respect for trying this out I've thought about making an estate shell but never got around to doing it. Your plaster of paris plug looks like it should give you a decent point to start from I take it you'll be shaving off the wood and filling the exterior hinge lines?
I'd stay away from making your own chassis at least in a money making sense. With the best will in the world I doubt you'll be able to make something better than an ABC, Tamiya, ect chassis for a price that most people would be willing to pay.

[olds_kool_lews]

Respect for trying this out I've thought about making an estate shell but never got around to doing it. Your plaster of paris plug looks like it should give you a decent point to start from I take it you'll be shaving off the wood and filling the exterior hinge lines?
I'd stay away from making your own chassis at least in a money making sense. With the best will in the world I doubt you'll be able to make something better than an ABC, Tamiya, ect chassis for a price that most people would be willing to pay.

thats correct, ill be shaving/sanding any details on the shell that aren't needed like the wood, or the external hinge lines, might even try smooth out the front door windows to make them more mk3 like.

i was thinking a flat sheet of ally for the chassis, with the holes drilled for which ever set upis chosen to use, but i suppose the pre-made tamiya/abc chassis would make more sence

so yeah, ill jus stick to making the shells if all goes to plan!

[DaveVader]

Few teaser pics:







They seem to show up allllllll the imperfections but it's pretty sound in the flesh.

Edited by DaveVader, 08 August 2010 - 10:14 PM.