1/8th Scratchbuild - Porsche RS60

[jaykay640]

Well i work for some german company making 1:1 cars :-)
I didn't ask for the supplier but they're definitely not chinese! The chinese will try to copy it once we put it into production. Until then they'll keep doing plastic :-)

A couple of years ago at the CeBIT computer show i saw a supplier that had a desktop laser system that would burn/cut a vector graphic into most materials. That would work nice for you now. The investment would be a bit out of control though:-) I had phantasies of getting one for doing photoetch...

Jelp is right. Maybe you can find some local company with a machine that does it for a reasonable price. They are not so uncommon anymore.

On the other hand, if you have the right mesh and get a useful chunk of it, you could lay it flat, make a silicone negative and then do thin positive copies from silicone or latex and cover the seat master with those "foils". It's being done like that on 1:1 clay design models to show textures on dashboards and door trim.

[cinqster]

Cheers for your help guys.

I'm going to ask around at some of the vinyl graphics guys near me this week regarding the lazer cutting idea. I've got a friend that can waterjet cut 1/4" steel but I think his setup might be overkill for this!

[zitzit]

Hi Cinqster!

I don't know where are you living, and if you are in hurry, but we have a laser engraving machine at work.

I think it would be powerfull enough to make little holes in a thin piece of leather (btw, I live in France).

MP-me if you are interested, It'd be free excepted for shipping fees.

Hope to see more updates in the near future.

Olivier.

[cinqster]

Well, guess it's time for an update.

The project is still very much live, though I've not got a lot to report on. I've put the bodywork on hold for a while as I need some more data so I'll be thrashing across Germany in May (with luck) to measure the car.

I went to the UK VolksWorld Show which has inspired me to pulll my finger out. The show had the usual stalls selling VW chrome tat that will rust before you get it home but I did discover a fab lady selling all sorts of brillant machine tools. Bought myself an indexable round profile lathe cutter that rocks!



I started to make the boss for the Porsche RS Werks wheel:



and then thought what he heck - I'll have a go at a dozen or so!

[jaykay640]

So we're heading straight into mass production, eh? Nice :-)

[klutz_100]

Originally Posted by jaykay640

So we're heading straight into mass production, eh? Nice :-)

Lovely steering wheel!

[cinqster]

Originally Posted by klutz_100

Lovely steering wheel!

It should be - that's nearly £1000 worth!

Unfortunately, it's not mine.

[cinqster]

Just a quick update as I tried my mill out properly for the first time this weekend.

A while back I bought a cheapo Indian made tilting rotary table. Mine doesn't have a Morse Taper (MT) hole in it and in hindsight I would recommend this feature as I had to dial in and centre the chuck using the four locating slots.



Needless to say everytime I had it aligned and tightened up the screws the darn thing would move! Took me three hours to centre it! Tempted to weld the thing in place now.

The table is actually good value for money and quite accurate but the etched dial is very inaccurate. I used a test piece and the slots looked dreadful. To get around this I measured the circumference of the table and made my own markings in Illustrator using a template. This paper strip is then help in place temporarily using double sided tape.



I made a sight marker too so that there's now little room for error. The red markers are for the 20 holes that I've still got to drill on the front of the brake drums.

Here's the first drum just about to have it's last couple of slots added (scuse my usual bad colour balance)



I'm rather chuffed with the final result - what do you guys think?



Just to make life really difficult Porsche decided to make the drums handed for either side, so I had to make two versions. From these two I will cast copies as I need to make four different versions. The front and back drums also differ so I will make a removable centre that will slot into each master thus giving me the 4 variations.

[gionc]

I understand nothing of the method, I guess I must READ this time ROFL

BTW the result is just WOW!

Yes absolutly fantastic.

[klutz_100]

I think you are having fun with this, aren't you?

Nice solution and it looks great

[godfather23]

I envy you for your time and joy for this detailed work. I basically have no clue what you are doing, but then again, it´s great watching. Try to stay with this and never give up on this magnificent project. In times of desperation just come to AF and we will kick your but to get on with it...

Robert

[lam90]

That is very impressive work you just completed on the brake drums. Sixty fins per drum and they all look identical. Great post and I can see why the setup time took so long.

This also means that your mill is back together and obviously working well. On top of that I also learned a new word "chuffed". Man what a great way to start your day.

Best regards,

Larry

[MPWR]

Spectacular- you should be chuffed. Terrific work, and they look spot on. That's exactly the way I would have gone about it, but I certainly didn't envy you the setup work when I first saw the pics of the 1/1 drums.

Took me three hours to centre it! Tempted to weld the thing in place now.

Can't say I blame you! But surely in the process it would be bumped out of alignment....

[Martin S]

Wow. Those brake drums looks complicated!
Imagine doing that by hand...
Results from your machining looks flawless.

[jaykay640]

How nice is that! Way to go!