E46 M3 cluster swap

[z31maniac]

That does look great!

[FredK]

That looks clean as hell!

[nando]

I read a tip on how modeling clay works well for thermoforming because it's cheap, holds it's shape, and is easy to form. I didn't do anything crazy, I just stuck a hunk of it to the back, and smoothed it over a little with my thumb. I guess as long as you don't overheat the plastic the thumbprint won't transfer over. :p

[Farbin Kaiber]

I was gonna say maybe SuperGlue, but looks like you solved it.

[nando]

attempt #3. I've got it nearly perfected. :)




I ended up using modeling clay to fill in the hole. it worked perfectly! you can't see it at all after thermoforming. the only slight defects are from the film - I left the top on this time. but it turns out much better because the defects could easily be polished out (unlike getting hair or dust in there like last time).




The clarity is pretty unreal for a home made part. I have 1 more sheet so I'm going to make another piece - this one is definitely useable, but there's a small crack in the corner. I'm going to glue it back together so it doesn't spread, and it'll be covered by the paint/vinyl sticker that Andrew made for me anyway.



I can only make one at a time because I have to dry the acrylic for 4 hours before forming it. I'll do my final pass next week, I should have 2 good ones to choose from. I also have 1 more full sheet of plastic I could make a couple more, maybe one to replace the lens I destroyed to make my mold. :p

[nando]

it doesn't seem to matter that much. there are some small scratches on the face that I took the edge off with some car polish, they didn't transfer to the formed part.

[AndrewBird]

I think you are over thinking this. Considering you only need it to work once or twice, I'd use whatever. Not like it needs to stay stuck for production use though.

I'd be weary of sanding on it though. Might end up turning into a lot of time polishing the lens.

[nando]

yeah I think that'll have the same issues as silicone. also lots of that stuff isn't compatible with acrylic.

I found a place that sells small disks of acrylic for like 15 cents, I could just make the hole a little bigger then glue it in, and polish.

[DEV0 E30]

silicone was a big fail. I finally got it to dry, but it stuck to the tape and pulled apart when I removed the tape. now I've got a mess to clean up. :p

I'm going to try an epoxy. any ideas for a hard epoxy that's compatible with acrylic that I can also polish reasonably well? I half want to try JB weld but that might be because I already have some...

In the spirit of finding things in the garage, clear caulking (for sealing windows/bathrooms)?

[nando]

silicone was a big fail. I finally got it to dry, but it stuck to the tape and pulled apart when I removed the tape. now I've got a mess to clean up. :p

I'm going to try an epoxy. any ideas for a hard epoxy that's compatible with acrylic that I can also polish reasonably well? I half want to try JB weld but that might be because I already have some...

[LJ851]

I actually am feeling bad for little kids right now. Playing an app on an iPhone instead of potentially blowing limbs or digits off.

Truth, i disassembled SOO many model rocket engines as a kid. Lots of friends got into making pipe bombs, vaporizing peoples mailboxes and putting big holes in the ground but i stayed slightly safer than that.

[Farbin Kaiber]

I actually am feeling bad for little kids right now. Playing an app on an iPhone instead of potentially blowing limbs or digits off.

[george graves]

lol. I did a lot of the same stuff. I'd probably be on a terrorist watch list or something these days. I still have some igniters leftover from model rockets.

Ha! Yep. Model rocket motors, if you peal off the cardboard, the propellent, well they do all sorts of fun. I stopped when I almost lost an eyebrow.

(oh hi NSA)

If you've never seen a trash can launched 100 feet into the air, with the amazing "Wooopbooommmmmmmmmmmmm!" you haven't lived.

[nando]

lol. I did a lot of the same stuff. I'd probably be on a terrorist watch list or something these days. I still have some igniters leftover from model rockets.

[Farbin Kaiber]

Looking back, I'm sure we are lucky these "tests" didn't leave us trying to deal with said item traversing the distance via a pathway through our bodies.

Used to make explosive punching balloons with Red Devil Lye and aluminum foil in one gallon metal cans and line our fence with a few and shoot at them with a bow and flaming arrows.