We make our own body panels for a Lada
Summary
TLDRIn this episode, the host introduces a vacuum forming machine, central to creating custom car parts. They announce new merchandise discounts, including hoodies, and demonstrate the machine's process of molding ABS plastic into panels. Challenges arise with power limitations and uneven plastic stretching, but the team successfully creates durable fenders. The video explores the cost-effectiveness of plastic parts versus metal, inviting viewers to share ideas for further applications.
Takeaways
- 🛍️ The video introduces new merchandise available on their website, including signature hoodies and other items like t-shirts, baseball caps, mugs, and document holders.
- 💰 A 25% discount is offered to the first 25 people who order the signature hoodies, with additional discounts on the entire product lineup.
- 🎁 With every order, a free sticker is included as a bonus.
- 🛠️ The main focus of the episode is a vacuum forming machine, which is used to mold plastic into various shapes for car parts like bumpers and fender flares.
- 🔨 The machine consists of a bench, frame, and uses a heating process with lamps to soften the plastic, followed by vacuum molding over a form or mold.
- ⚡️ The machine requires a significant amount of power, but the team finds a workaround by using a smaller configuration to accommodate the facility's power limitations.
- 🔧 The process involves placing a sheet of plastic onto the frame, heating it, and then molding it over a form while applying vacuum to achieve the desired shape.
- 🚗 The team attempts to replicate a car door panel and front fenders using the vacuum forming machine, experimenting with different materials and thicknesses of plastic.
- 🔄 They encounter challenges such as uneven plastic distribution and vacuum leaks, but manage to produce usable plastic panels despite these issues.
- 💡 The video highlights the cost-effectiveness of using plastic for car parts compared to metal, with significant savings on materials and production costs.
- 📈 The vacuum forming machine is a valuable tool for custom part production, especially for those with experience in the field, and the team invites viewers to share their ideas and suggestions.
Q & A
What is the main focus of the episode described in the transcript?
-The main focus of the episode is the introduction and demonstration of a vacuum forming machine used for creating various plastic parts such as bumpers, fender flares, and other panels.
What kind of merchandise is being promoted in the video?
-The merchandise being promoted includes signature hoodies, t-shirts, baseball caps, mugs, document holders, and stickers, all available with discounts on the website.
What special offer is made for the first 25 customers who order the signature hoodies?
-The first 25 customers to order the signature hoodies are offered a 25% discount on their purchase.
What material is commonly used with the vacuum forming machine for creating plastic parts?
-ABS plastic is commonly used with the vacuum forming machine for creating plastic parts due to its workability with this type of equipment.
What is the issue with the power requirements of the vacuum forming machine?
-The vacuum forming machine requires 48 kilowatts of power, but the facility has a limitation of approximately 30 kilowatts, which restricts the use of all 48 lamps simultaneously.
How is the plastic sheet secured in place on the frame before the molding process begins?
-The plastic sheet is secured in place on the frame using silicone seals that tightly press against the sheet, and it is pinched all around to lock it in place.
What is the purpose of the vacuum pump and reservoirs in the vacuum forming machine?
-The vacuum pump and reservoirs are used to create a vacuum that sucks down the hot plastic and wraps it tightly around the mold on the tabletop, forming the desired shape.
What was the initial problem encountered when trying to mold a door panel?
-The initial problem was that the vacuum leaked out, preventing the plastic from stretching out evenly and resulting in a puffy and half-baked appearance in some areas.
How did the team improve the molding process for the front fenders?
-The team improved the molding process by honing their skills, using one mil thick ABS plastic and HDPE plastic, and ensuring a proper fit and vacuum application.
What is the advantage of using plastic panels over metal parts in certain applications?
-Plastic panels are advantageous in applications like drift cars where aesthetics are less critical because they are cheaper to make, lighter, and can be easily replaced if damaged.
What was the cost of the vacuum forming machine mentioned in the transcript?
-The vacuum forming machine cost a bit under 300,000 rubles, or approximately four thousand US dollars, including shipping.
Outlines
🛠️ Introduction to Vacuum Forming Machine and Merchandise Promotion
The script introduces a vacuum forming machine, which is the main focus of the episode. The host announces new merchandise available on their website, including signature hoodies, and offers a 25% discount for the first 25 customers. Other items like t-shirts, baseball caps, mugs, and document holders are also available with discounts. The host then provides a quick overview of the vacuum forming process, explaining the machine's components, including the bench made of thick plywood with a coating and slots for creating a vacuum effect. The process involves heating ABS plastic sheets and molding them over molds placed on the bench, using the machine's heat and vacuum to form the plastic into the desired shape.
🔧 Exploring the Vacuum Forming Machine's Operation and Challenges
This paragraph delves into the operation of the vacuum forming machine, discussing the power requirements and limitations due to the facility's power capacity. The host describes how to heat the plastic sheet by lifting the frame and switching on the necessary lamps, depending on the size of the plastic sheet. The process of creating a vacuum to mold the plastic is explained, including the use of a vacuum pump and accumulators. The host attempts to replicate a door panel, facing issues with uneven plastic stretching and vacuum leaks, which result in an imperfect mold. Despite the challenges, the host remains optimistic about the potential of the machine and the process.
🚗 Creating Plastic Panels for a Car Using the Vacuum Forming Technique
The host proceeds to create plastic panels for a car, starting with front fenders. They discuss the process of preparing the mold, using HDPE plastic as an alternative to ABS for better flexibility and less brittleness. The host compares the results of using one mil and two mil thick ABS plastic, noting the difference in rigidity and appearance. They successfully fit the plastic fenders onto a car, using rivets for attachment, and discuss the potential applications for such plastic panels, especially in situations where appearance is less critical, and the cost savings compared to metal parts.
💰 Conclusion on the Cost-Effectiveness and Future Applications of Vacuum Forming
In the final paragraph, the host wraps up the episode by discussing the cost-effectiveness of using the vacuum forming machine for creating car parts. They compare the cost of materials and electricity to the price of traditional metal parts, highlighting the significant savings possible with plastic parts. The host invites viewers to share their ideas and experiences with the machine and different types of plastic, expressing interest in exploring further applications. The cost of the machine is also mentioned, along with an invitation for viewers to subscribe to the channel for more content.
Mindmap
Keywords
💡Vacuum forming machine
💡Merchandise
💡Discount
💡ABS plastic
💡Molding
💡Silicone seals
💡Lamps
💡Vacuum pump
💡Reservoirs
💡Rivets
💡HDPE plastic
Highlights
Introduction of vacuum forming machine as the focus of the episode.
Announcement of new merchandise, including hoodies with a 25% discount for the first 25 orders.
Detailed description of the machine's components: bench, frame, and plywood coating.
Explanation of the vacuum effect created by slots milled out in the bench.
Discussion of the types of plastic used, such as ABS plastic, for molding body panels.
Demonstration of placing a plastic sheet into the frame and using silicone seals to secure it.
Challenges faced due to the machine's power requirements exceeding the facility's limits.
Use of only 15 lamps for smaller panels to manage power consumption.
Step-by-step guide on heating the plastic sheet and molding it onto the bench.
Introduction of vacuum reservoirs as vacuum accumulators for shaping plastic.
Experiment with a Volkswagen door as a mold and addressing vacuum leakage issues.
Comparison of different plastic thicknesses (1mm and 2mm) for making fenders.
Evaluation of the results: 1mm plastic for better appearance and 2mm for durability.
Cost-effectiveness of plastic panels compared to metal parts, highlighting significant savings.
Encouragement for viewers to suggest ideas for future projects and improvements.
Conclusion with the machine's cost and a call to action to subscribe to the channel.
Transcripts
foreign
hello everybody so that thing behind me
is called a vacuum forming machine and
it's going to be the center of focus in
this episode so have I got some good
news for you fellas some cool new merch
available on our website like for
example these sweet signature hoodies
and the good news doesn't end there
the first 25 people to order these
hoodies we'll be offering them a 25
discount and don't forget that there's a
bunch of other stuff that you can order
on our website t-shirts baseball caps
mugs document holders and we're offering
some generous discounts on the entire
lineup and on top of any order you make
we'll throw in one of these stickers on
the house don't miss your chance to get
some merch at discount prices hit the
link in the video description and grab
yourself something let me give you a
quick rundown on what we're dealing with
here the machine itself consists of a
bench a frame
and I'd say that the bench is the most
important element of all it's made out
of
some really thick plywood plus there's
some kind of coating that I don't know
the right name for some sort of paint I
guess
you've got a bunch of slots milled out
which are there to create the vacuum
effect
you'd often see all kinds of bumpers
fender flares and other panels now those
are made using ABS plastic
which is great to work with using this
type of equipment
I've got a piece
right here if you put some heat into it
you can mold it into any shape you want
that's what this machine is for now
allow me to show you what it's made of
and go through every stage of how it
works you and I still don't have a
complete understanding
the process of molding a body panel
starts with us placing a sheet of
plastic into the frame
we've got that right here and I have to
say it's pretty massive
but I suspect that'll make it all the
more reliable
here I've got my plastic sheet my blank
ETS we place it onto the frame and on
the frame we have silicone seals that
tightly press up against the sheet in
order to secure it in place
and so now
we've locked it in place
you pinch it all around
and so now
up top we've got a bunch of lamps
48 of them to be exactly
each putting out one kilowatt and that
actually creates uh
a few problems for us you see when we
bought this machine it didn't occur to
us that it needs so much power
unfortunately our facility has its
limitations
approximately 30 kilowatts is as much as
we can afford to use in here
but the machine needs 48. however there
is a way out you can see that this sheet
is pretty small 1 by 1.5 meters and so
we'll be using the smaller configuration
of the machine
uh for this instead of the full 48 we
can flip on just 15 lamps
if we want to make small sized panels in
order to heat the plastic we need to
lift the frame
then we switch on as many lamps as we
need if we were to place a two by two
meter sheet which is the limit of what
the frame is going to allow us
we'd have to switch on all 48.
but with a smaller sheet we only need
15. United lamp it takes a few minutes
for it to get up to the right
temperature
this machine is capable of shaping
plastic anywhere from one end all the
way up to eight millimeters thick
now as soon as the lamps put enough heat
into this sheet of plastic
we place anything we want onto the bench
for instance we can use a canister as a
mold and after that we drop the hot
plastic onto whatever is down here
right now this isn't going to work
because at the moment the machine is not
powered up and the plastic is cold that
said it's supposed to mold into the
shape of whatever is on the bench
mostly after that we need to release
the vacuum
and all of the air that used to be under
the sheet evacuates into dedicated
receivers
Ary leaving us with an exact copy of the
panel that we had placed on the machine
if we need to once the panel is on the
bench and is no longer hot we can eat in
some air
we connect an Air Supply to our machine
and the reason for doing that would be I
guess the point is to help separate
everything now let's have a look inside
the machine all of these Breakers are
there in order to let you set up the
circuitry in such a way that not all the
lamps shine but instead just those you
need you also got
the vacuum pump which is located in
plain sight
the pump itself is unable to quickly
create a vacuum but that's what those
two big reservoirs are for each with a
capacity of 100 liters essentially those
are vacuum accumulators
the vacuum builds up inside of them and
then that vacuum sucks down the hot
plastic and wraps it tightly around
whatever is on the tabletop it's
actually a very simple layout with one
artery routed to the reservoirs from the
vacuum pipe
and you've got a second one beating the
air for I don't know
separating the two pieces I think it
basically only consists of a single pipe
that's routed straight to the tabletop
[Music]
it didn't take too long for us to find a
panel to replicate in plastic here it is
a dwarf from a lot of wagon
the idea is to take this here door
and as to avoid it being damaged by the
vacuum
we'll stuff it with some of this used up
styrofoam
so we always stick these in and fill it
with some regular old construction foam
now I reckon that this should be enough
to keep the door from caving in under
all of that pressure but let's try this
out and see if I'm right
problem
[Music]
so the door is prepped I mean to say the
mold is ready is this going to work or
is it not let us know in the comments I
can't even start to imagine now long
story short we filled the inside of the
door with foam on the other side we've
filled any potential gaps with foam for
the sake of making the process a bit
easier and then we cut off all excess
foam at an angle of
over 90 degrees so that we have less
trouble separating the plastic from the
mold the door itself feels much sturdier
it no longer bends when you press on it
with your hand that's definitely a good
thing but now it's time to turn the
machine on look at how you start this
thing we flip the switch and it's on now
we need to engage the vacuum pump here
we've got a pressure gauge and the
switch for the pump
now it's on and the pressure is going
into negative values I think we need to
wait a couple of minutes for
example to create enough vacuum
we will be placing the plastic so that
the coarse part faces down we would
prefer the door to be smooth
that's the right way to go I reckon
otherwise if later we were to wrap or
paint it we'd either have to prep the
whole thing
or it would just be all rough and
unpleasant to the touch
now we drop the frame with the plastic
in the middle
and while raising the frame we place the
dorm
now we do have
a slight problem it sort of fits onto
this small
section but barely
okay now we flip on
the 15 lamps now according to the
information I found on the internet ABS
plastic becomes malleable at around 180
degrees Celsius so far when I touch it
yeah it doesn't seem any soft terms it's
only been like 30 seconds and you can
really feel that it's hot
after two and a half minutes the plastic
has become really soft it's now sagging
by about 20 centimeters
you can see some kind of steam or smoke
emanating from it
looks pretty sinister
the plastic is now very soft I guess I
need to flip on the vacuum pump I need
to do this the right way and quickly
the plastic is soft as can beam
lights off dropping the plastic and now
vacuum
I don't know exactly what that sound was
but I think it might have been glass
[Music]
I can tell that we were unable to make a
proper even and smooth door
first off I can already see a wrinkle in
there
I'm guessing there just wasn't enough
material to wrap around I mean there's
literally just an extra two centimeters
around the perimeter I guess the store
is going to require the extended table
so that we have a bit of wiggle room
okay now I think I can see the problems
we were dealing with
I'd of course prefer to do this
carefully without breaking anything even
if the glass did shatter I still think
we can save this mold of ours
I mean so far this is looking pretty
good
let's just extract it
together with the door
and immediately we see a few problems
this might have also prevented us from
stretching the plastic out evenly
as you can see we have a breach through
which the vacuum leaked out apparently
okay there we are
it looks pretty nice from the inside
on the outside it also ain't half bad
but this is definitely far from perfect
since we were unable to follow these
lines
as a result it looks a bit puffy and
Half Baked in this area
if the vacuum didn't leak out I think
this would have
turned out pretty good it was much
better than what we see here
[Music]
I was able to find a couple of front
fenders they're brand new and almost
even intact though they were dented a
few times while they were being
transported so we're going to convert
them into molds and given the space we
have on the bench which we've configured
to one by one and a half meters on these
it should be way easier to make a proper
panel out of plastic let's get to work
[Music]
thank you
and here we have the molds for the front
fenders this time it was a much simpler
job I mean we have honed our skills and
now we try making plastic copies
this time we'll be using one mil thick
ABS it really seemed to me like the two
mil was a bit much when we did the doors
so this time it'll be one mil and I've
prepared some hdp plastic
which can be heat molded and is much
better than ABS in that it doesn't get
as brittle when it's frozen
so it's a better material than ABS all
around
let's try using it to mold one Fender
and one millimeter ABS or the other one
and see what comes out of it
oh
HDPE plastic
foreign
[Music]
one mil ABS plastic
let's try this out
[Music]
it looks fantastic
we got the right shape but I can already
tell that plucking it up is going to
require quite some effort the plastic
has crushed the foam a bit I guess I
gave it too much vacuum
but overall the fender looks really good
[Music]
two mil ABS plastic
[Music]
foreign
[Music]
so we've made ourselves a couple of
fenders one of them using two mil ABS
plastic
for comparison here are a couple of one
mil thick fenders the difference in
rigidity is pretty amazing this one is
like a rag though I'm sure once we rivet
it it'll look much better
it very well might behave okay on a car
and not really be affected by the air
current we won't know for sure until we
try as for the two mil plastic weld that
makes for a properly durable panel that
you can safely install onto a car I
expect this to do its job really well
but if I'm being honest I prefer the
look
of this one mil panel in my opinion the
one mil panel looks way better than the
thicker two mil
now let's go ahead and fit this to a car
and see how that works out will these
fenders work if you were to use them on
a drift missile
drift Karcher
[Music]
what's wrong and here we are the panels
fit nicely
we used about 10 rivets for each fender
so they're on there pretty tight
at a glance you can barely even tell the
difference from a metal fender well if
that were to be cut and riveted just
like this if you were to find a way to
make an edge and secure it on the inside
well I'd say that until you touch it you
wouldn't even be able to tell the
difference with it following the shape
so closely
one more thing I'd like to point out in
the context of drift missiles and stuff
like that
when speaking of applications where you
don't necessarily need the car to look
good well these work pretty well in that
sort of situation now it's just a matter
of making molds off of all the panels so
that we can make anything we need
I still don't know how the plastic is
going to behave in freezing weather how
brittle it's going to become
but in any case such panels are way
cheaper to make than metal Parts even if
we're talking about something like a
fender if you were to take a 1.5 by 3
meter sheet of two millimeter ABS
plastic so you slash that in half and
you're looking at 800 rubles or about
ten dollars a piece
obviously if you buy a bunch of them
that'll lower the price even further
then there's the cost of electricity
let's call it a thousand rubles a single
front fender goes for like 1500
meanwhile a new rear fender for this
model will cost you ten thousand rubles
and you can't find them in stock at
least that's the current situation in
novaersk I'd say this is a pretty useful
device
if you have any sort of experience let
us know in the comments what we can make
or which sort of plastic is better
suited for the purpose hit us up we will
read through your ideas I'm sure you'll
send in some good ones that would be
worth us giving a try I'm sure a lot of
people might be curious as to how much
that machine costs well we got it at a
bit under 300 000 rubles or four
thousand dollars including shipping the
manufacturer is located over 1 000
kilometers away from us
I think we got a pretty good deal
considering this is the biggest machine
of this type that you can buy like I
mentioned earlier this machine is two by
two meters
and that's it for this episode
would you subscribe to the channel so
you don't miss our latest exciting
content I'll be waiting to see what
ideas you share in the comments thanks
in advance that'll be all see you later
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