bespoke plastic design... [Archive] - SV650.org

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inevitable

24-04-07, 07:53 PM

Since I smashed the front of my new Kawasaki Versys http://www.kawasaki.co.uk/versys/default.asp?Sub=654AAA5 I've been having a think (thunk)...

Rather than go for the complete streetfighter, ( me being rather mechanically inept), I've realised that I can keep the undamaged headlight etc all as-is.

As I was 45 degrees when I hit the chav-car, the screen, screen brackets and sub-frame took the hit. The only parts that really need replacing are the left and right fairings, the front sub-frame bit that holds the lights, the upper cowling that hides the light and cables and the screen brackets and screen.

Sooooooooo... what I was thinking, is that I replace the front sub-frame and get the lights straightened out instead of pointing at 11 o' clock, which leaves me £400 odd quid to design a new front fairing, incorporating a low-rise "front screen" but all in ebony black plastic. Imagine a stealth bomber... naked-but-not Versys. http://www.versys.co.uk/forum/Smileys/default/7.gif

Here's the problem. I don't know of anyone that'll do a bespoke plastic molding. It would need to be a small firm I think. So, I'll be phoning around over the next few weeks to see if there's anybody out there.

Any streetfighter / project experts out there who have experience of this?

Also... (longshot) does anyone know a plastic molding firm that might be of use???

Looks like the loud exhaust might have to wait for a few months http://www.versys.co.uk/forum/Smileys/default/embarrassed.gif

Thanks for any help ;)

socommk23

24-04-07, 11:46 PM

make one yaself with some fibre glass!

svpilot

25-04-07, 01:10 PM

I think you will find the tooling cost for injection moulding prohibitive. Great for 1000's pcs, not so good for a 'one off' That said, if you come up with a good design, you may be able to sell it... maybe even make money :D
Anyhoo, I'm not sure how big a part they can do, but these guys are pretty good for small runs... you need to give 'em 3D data though.
www.protomold.com

Fibreglass may be your best bet :-?

HTH

Laters....

inevitable

25-04-07, 03:22 PM

eyethankewe!

I hadn't thought of FG and protomold is as good a start as any 've tried so far. I think the FG route may be easier though... surfboard and canoe makers reckon they can do anything with it...

gettin2dizzy

25-04-07, 07:08 PM

GPR would be perfect. i'd replace it with something different if i was you, I think the back and sides look ace- but that front light just doesn't work!

northwind

25-04-07, 10:03 PM

Most plastics are formed around a metal mould, meaning minimum runs in the hundreds... Fibreglass all the way. If you're moderately handy and very patient you could do it yourself- and once you've done it in fibreglass, you can reuse your buck and do it in carbon fibre :smt109

squirrel_hunter

25-04-07, 10:26 PM

northwind

25-04-07, 10:33 PM

He's a good example- but he's really good. He's on the cover of one of the US magazines this month btw
:rave:

squirrel_hunter

25-04-07, 10:37 PM

Yep he's very good!

He's the reason I have a copy of the Fibreglass Manual...

inevitable

25-04-07, 10:48 PM

Yep he's very good!

He's the reason I have a copy of the Fibreglass Manual...

is there really a fibreglass manual? :eek: or are you taking the p1ss?

squirrel_hunter

25-04-07, 11:10 PM

The Fibreglass Manual (http://www.amazon.co.uk/Fibreglass-Manual-Practical-Reinforced-Plastics/dp/1861265751/ref=pd_bbs_sr_1/203-4480319-9165559?ie=UTF8&s=books&qid=1177542221&sr=8-1)

I got this as I wanted a hard copy reference, plus it was cheap and has a pic of an R1 on the front. The book covers the basics not so much on Carbon Fibre but a good base point. Tygaboys posts over at BARF basically say the same things, the book has a bit more detail and a couple of different approaches but I feel its worth a read.

I shall be placing an order for some materials soon, once I find a good supplier.