I’m fascinated by this project and your skills. I discovered the channel a week ago and have watched all the Jaguar episodes. I’m happy you’re still working on it. Keep it up, I want to see this to the end.
Absolutely superb job Danie, I managed to catch up to the current episode. I am blown away by your creative abilities. For the headlight lenses I would recommend a heat gun then clamping it between the plates and fabric but either way it turned out beautiful. Thank you for sharing your journey, I eagerly await the next part 🙂
Polycarbonate can be formed without the bubbles, but it is a PITA. The bubbles are formed from water that has been absorbed from the air, so it's necessary to preheat it at a lower temp to dry it out. Even then, the temperature range between under and over cooking is pretty narrow, which I found really difficult to deal with working with a cheap old kitchen oven and I can't imagine the frustration (and expense in failed attempts) of trying to work with a piece too large for an oven. I worked with it once on a set of headlight covers that were a close set of compound curves (though nothing like a D-Type) and that was the last time I've used it for anything not flat! I like your solution to the problem. I lack your metal skills, so I would have used a covered foam mold and a vacuum former for the headlight covers.
If you have all the set up to make the lenses, you should make 2 sets, maybe even 3 sets, so that one day when one chips or cracks you have a spare and don't have to redo the whole process. Its looking very very awesome now.
Nice new tune at the 2 minute mark, I dig it. It fit the stump shaping really well. Also, a MAPP torch works great for flame polishing edges of plastics. I couldn't see if you had done it but it sounded rough when you ran your finger along the windshield so I assume not yet. Practise on offcuts till you get confident.
The polycarbonate if you were not aware comes different ratings and also in tinted sheets as well as the clear, there is opaques and blacks we used when building safety guards for bottle filler plants in case a glass bottle exploded on the line.
Great channel and build, please keep sharing the nice work!! Just as an improvement, I’d rather use motorbike screen rubber nuts for the headlight covers than standard rivet nuts. It would absorb vibration and avoid a premature crack, maybe rubber washers would do the part as well.
Your way of forming the lenses was certainly with loving craftsmanship although it’s extremely time consuming. I’m wondering if it could have been done more easily using a vacuum form. You would only need one positive mold (possibly even building it from sculpted clay inserted into the headlight voids) and then laying the molten polycarbonate on top of the mold while sucking it tight using vacuum pressure. I’ve seen lots of clear domed skylights made this way.
Try the "stretch T-shirt" method. Clamp half the cloth around one side, and then pull the cloth tightly over the plastic, and clamp as you go. I used to make motorcycle helmet visors this way.
I thought you might well have a problem moulding those lenses but you took your time, thought it out very carefully re-heating several times did the trick. Like someone else as said, you need to make at least one spare set.
I'm glad to hear if reheating is normal, I actually didn't know what else to do. Will definitely be making more lenses. Ps. I'm a huge fan of your work!
Fun fact: polycarbonate absorbs water, so when you heat it it bubbles out forming the bubbles. If you bake it just below 100C you can drive the moisture out then cook it to shaping temperature, it can even be welded!
Wicked cool. Stumbled on your channel and I'm blown away. This is coach building straight up. I wonder if a vacuum bag would work for he headlight forming. I used those clothing and bedding vacuum bags for forming kydex holsters and it worked well.
Thank you very much! Vacuum bagging is definitely an option but with limited resources and a normal household oven this method seemed best (for my application of course).
Great job on both of the clear bits. A simpler way to make the headlamp covers is by only making one mold/buck... Put your plastic in an oversized "frame" to heat it up in the oven. Then pull it out while it's hot and push the mold into the center of the hot plastic. This will stretch the center and keep the edges from wrinkling since they are being held by the frame around the perimiter. You need to heat the plastic a lot hotter so that it starts to deform and droop in the middle. THere is a fine line with acrylic between the right forming temperature and creating bubbles but it will be over 300* F.
Mooi man.... I was a bit worried to see the ripples on the sides, but watching them dissappear when you flipped them was awesome... Can't wait to see this next week. It's going to CiTP right?
Polycarbonate is hydroscopic...that's where the bubbles come from. To heat form the stuff, you have to bake it at a low temperature in a dry environment for up to a day. This will cause the absorbed water to evaporate away without making the bubbles. THEN, you can have at it with higher heat. Beware though, heat tend to make the stuff release phosgene gas which can irritate your airway to the point where it will bleed and you will drown in your own blood. Phosgene was one of the popular gasses used as weapons during WWI... And since.
@@BroughBuilt I would...if the oven was far away from where I slept! I learned that stuff the hard way back in the land before internet. I was tasked with building guards for production machines in the late '80s. I got a nasty scratchy throat almost immediately when I applied heat like I would've with acrylic. The MSDS sheet was shipped with the product and I looked it over before calling the vendor for some forming tips...YIKES!
I did some similar thigs with heating and molding the acrylic, I managed to get hold of an old vacuum former which makes it easier , but the perspex is so brittle i'm going to try some polycarb next th-cam.com/video/wlztLTb5QuU/w-d-xo.html this is on a kids d type and 2mm acrylic
![เกิดใหม่ทั้งทีก็เป็นสไลม์ไปซะแล้ว ซีซั่น 3 - ตอนที่ 64 [ซับไทย]](http://i.ytimg.com/vi/Pmsta0byEpk/mqdefault.jpg)
What a great craftsman added to an ability to teach in a timely way without sending your audience to sleep. Brilliant.
I’m fascinated by this project and your skills. I discovered the channel a week ago and have watched all the Jaguar episodes. I’m happy you’re still working on it. Keep it up, I want to see this to the end.
Thank you very much! I can almost see the finish line 😁
I have been waiting eagerly for another episode on the D-Type. Thank you.
Exquisite craftsmanship and creative problem solving on the headlights- brilliant! This is truly inspiring
Thank you!
Absolutely superb job Danie, I managed to catch up to the current episode. I am blown away by your creative abilities. For the headlight lenses I would recommend a heat gun then clamping it between the plates and fabric but either way it turned out beautiful. Thank you for sharing your journey, I eagerly await the next part 🙂
Thank you! I actually want to try making one using the heat gun only. Wasn't sure whether it would work 🤔
Your craftsmanship ability is outstanding keep it up 🔥
Thanks Jan!
Polycarbonate can be formed without the bubbles, but it is a PITA. The bubbles are formed from water that has been absorbed from the air, so it's necessary to preheat it at a lower temp to dry it out. Even then, the temperature range between under and over cooking is pretty narrow, which I found really difficult to deal with working with a cheap old kitchen oven and I can't imagine the frustration (and expense in failed attempts) of trying to work with a piece too large for an oven. I worked with it once on a set of headlight covers that were a close set of compound curves (though nothing like a D-Type) and that was the last time I've used it for anything not flat! I like your solution to the problem. I lack your metal skills, so I would have used a covered foam mold and a vacuum former for the headlight covers.
I have been learning a lot by watching you, thanks
Beautiful work, well done!
If you have all the set up to make the lenses, you should make 2 sets, maybe even 3 sets, so that one day when one chips or cracks you have a spare and don't have to redo the whole process. Its looking very very awesome now.
I will be making an extra set for that exact reason. It was sooo stressful drilling the mounting holes 😱. Only ran out of time for the video.
I love to watch you build my dads car thanks
Nice new tune at the 2 minute mark, I dig it. It fit the stump shaping really well. Also, a MAPP torch works great for flame polishing edges of plastics. I couldn't see if you had done it but it sounded rough when you ran your finger along the windshield so I assume not yet. Practise on offcuts till you get confident.
Fantastic, I've been eagerly waiting for progress on the XKD.
The polycarbonate if you were not aware comes different ratings and also in tinted sheets as well as the clear, there is opaques and blacks we used when building safety guards for bottle filler plants in case a glass bottle exploded on the line.
I know about the different colours but wasn't aware it came in different ratings 🤔.
Great channel and build, please keep sharing the nice work!!
Just as an improvement, I’d rather use motorbike screen rubber nuts for the headlight covers than standard rivet nuts. It would absorb vibration and avoid a premature crack, maybe rubber washers would do the part as well.
Thanks for the great tip! I will get those rubbers.
The car is a testament to your skill👍 I see some D type screen supports incorporate a rear view mirror
good job so far!
Your way of forming the lenses was certainly with loving craftsmanship although it’s extremely time consuming. I’m wondering if it could have been done more easily using a vacuum form. You would only need one positive mold (possibly even building it from sculpted clay inserted into the headlight voids) and then laying the molten polycarbonate on top of the mold while sucking it tight using vacuum pressure. I’ve seen lots of clear domed skylights made this way.
Very Nice!
Superb work mate
Try the "stretch T-shirt" method. Clamp half the cloth around one side, and then pull the cloth tightly over the plastic, and clamp as you go. I used to make motorcycle helmet visors this way.
Thanks. I'll look into the method. Sounds like a good idea
Impressive indeed. I imagine each mould must take a couple of hours to hammer and roll?
I thought you might well have a problem moulding those lenses but you took your time, thought it out very carefully re-heating several times did the trick. Like someone else as said, you need to make at least one spare set.
I'm glad to hear if reheating is normal, I actually didn't know what else to do. Will definitely be making more lenses. Ps. I'm a huge fan of your work!
Excellent job....
His name is Donny short for Donald which suggests he's Scottish in which case I'm so proud of this kinsman genius.. So glad the Jag is back.
Its Danie, the Afrikaans version of Danny/Daniel. And yeah, this man's a genius.
Hello.
Maybe there is another to mold plexy but your way to do it is fantastic.
Your car is getting better and better.
Thank you Miguel! Getting there 😃
Fun fact: polycarbonate absorbs water, so when you heat it it bubbles out forming the bubbles. If you bake it just below 100C you can drive the moisture out then cook it to shaping temperature, it can even be welded!
Very tidy ☝️👏👏👍👍
Beautiful
Masterpiece..., 👍👍👍👍
Wicked cool. Stumbled on your channel and I'm blown away. This is coach building straight up. I wonder if a vacuum bag would work for he headlight forming. I used those clothing and bedding vacuum bags for forming kydex holsters and it worked well.
Thank you very much! Vacuum bagging is definitely an option but with limited resources and a normal household oven this method seemed best (for my application of course).
¡ What a skill !
Looks amazing, very well done. Do you know how much it weighs so far?
Great job on both of the clear bits. A simpler way to make the headlamp covers is by only making one mold/buck... Put your plastic in an oversized "frame" to heat it up in the oven. Then pull it out while it's hot and push the mold into the center of the hot plastic. This will stretch the center and keep the edges from wrinkling since they are being held by the frame around the perimiter. You need to heat the plastic a lot hotter so that it starts to deform and droop in the middle. THere is a fine line with acrylic between the right forming temperature and creating bubbles but it will be over 300* F.
That is a very good idea. I will definitely be trying that method in the near future. Thanks for the comment.
Good job indeed, as usual 👍.
I wonder where is your coffee bro 🤔 .. 😄😄.
Haha thanks! Savoured the coffee moment off camera this time 😁
Mooi man.... I was a bit worried to see the ripples on the sides, but watching them dissappear when you flipped them was awesome... Can't wait to see this next week. It's going to CiTP right?
Thanks Gary. Absolutely gonna be there. Looking forward to meeting up again
Ek het nie die geduld of tyd wat jy doen nie maar dit is n job van geduld en inspirasie.Miskien eendag op n reendag.
Id love to learn from you and do the same thank for building the jaguar from James Kruger
Thanks James. You must visit one day and I will teach you the basics👍
I wil thanks
Respect
👍🏻
Maestro
👍
Polycarbonate is hydroscopic...that's where the bubbles come from. To heat form the stuff, you have to bake it at a low temperature in a dry environment for up to a day. This will cause the absorbed water to evaporate away without making the bubbles. THEN, you can have at it with higher heat.
Beware though, heat tend to make the stuff release phosgene gas which can irritate your airway to the point where it will bleed and you will drown in your own blood.
Phosgene was one of the popular gasses used as weapons during WWI... And since.
Very interesting and insightful comment thanks. I feel like I'm not gonna be putting polycarb in the oven any time soon 😁
@@BroughBuilt I would...if the oven was far away from where I slept!
I learned that stuff the hard way back in the land before internet. I was tasked with building guards for production machines in the late '80s. I got a nasty scratchy throat almost immediately when I applied heat like I would've with acrylic. The MSDS sheet was shipped with the product and I looked it over before calling the vendor for some forming tips...YIKES!
@@Bluswede Yikes indeed!
How about moving your left hand out of the way so we can see the video.
What temp and what cloth material?
Hi. I want to use tan leather
I did some similar thigs with heating and molding the acrylic, I managed to get hold of an old vacuum former which makes it easier , but the perspex is so brittle i'm going to try some polycarb next th-cam.com/video/wlztLTb5QuU/w-d-xo.html this is on a kids d type and 2mm acrylic
Just watched your video. Very cool! I would love to purchase a vacuum former in future. It will definitely give the best results.
Vacuum forming is easier to get a good result
I think so too. Maybe I'll invest in that in future
Jinne pel, jy bou iets besonders.