material to easily form compound curves for car parts

[krcaddis]

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

 

[MikeHalloran]

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.

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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

 

[jedward]

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

 

[unclesyd]

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

http://www.dynamold.com/shim.htm

 

[unclesyd]

One of them brain things came along and I thought about using prepegs. This is just one of many.

http://www.ambercomposites.com/products/composite/component-systems/prepreg/

Here is a very good source for mold making materials.

http://www.freemansupply.com/index.htm