hard to find plastic parts and pieces

[King Peetis]

I have tried my hand at making hard to find plastic parts. I'm in the process of making a mold and casting the little black clips that hold down the privacy panel in the hatch. I will post some pics soon. Meanwhile, I need you guys to post some pics of hard to find parts I could try making.

[Legend_master]

clips that hold the trim to the doors and rear quarter panels. As well the plastic guide for the throttle cable that attaches to the firewall.

[King Peetis]

clips that hold the trim to the doors and rear quarter panels. As well the plastic guide for the throttle cable that attaches to the firewall.

yours will be the third I make right after I make the "t" handle for lifting the same privacy panel in the hatch.

[Legend_master]

Started thinking about it, drivers side door lock switch. Most people don't pull the handle yet still try to lock the drivers door. Usually ends up with a broken door lock switch. Not really worried about it being chrome with orange insert. How more is it to change the color of the plastic?

[2oodoor]

How about a nice fitting plastic guard for the door panel seat belt crunch damage!?
Paintable visors!
Invent Inside flip visor extentions for us tall people who have the seat all the way back.

[Shawn87AccordDx]

Door panel for sure.


My blog: http://shawnseeley.com

[King Peetis]

OK, Im trying to post some pics but dont know how with this new format--whats the dillio?

[Stealth]

.

[Legend_master]

OK, Im trying to post some pics but dont know how with this new format--whats the dillio?

Try uploading to Photobucket, I've had pictures on here hosted by them for years now.

[King Peetis]

Well this is my first attempt and it came out pretty good. Actually this is my forth pour but the first one in black. It took some time before I found a resin that was suitable for the application. The first resin I used was too soft, then I tried a polyester resin that was too rigid. The one made by Alumilite is juuuuust right!!! I also struggled with air bubbles and the resin setting up too fast in the mold. Here are several random pics to show my progress. I will post more of a step by step later.

Heres the part I was talking about...
http://img14.imageshack.us/img14/694/originalpartandmold.jpg (http://imageshack.us/photo/my-images/14/originalpartandmold.jpg/)

Kind of a close up of the mold
http://img703.imageshack.us/img703/8929/siliconemold.jpg (http://imageshack.us/photo/my-images/703/siliconemold.jpg/)

Alumilite is great stuff.
http://img339.imageshack.us/img339/7253/resin.jpg (http://imageshack.us/photo/my-images/339/resin.jpg/)

Gotta pour quick or you could be in trouble...
http://img809.imageshack.us/img809/7636/castingi.jpg (http://imageshack.us/photo/my-images/809/castingi.jpg/)

The part I made is to the right in the pic
http://img547.imageshack.us/img547/3162/oemandhomemade.jpg (http://imageshack.us/photo/my-images/547/oemandhomemade.jpg/)

[King Peetis]

Try uploading to Photobucket, I've had pictures on here hosted by them for years now.

I was stuck in 'Quick Reply' for some reason. I had to exit out then go back in...

[Legend_master]

if you ever wanted to make some extra money, you should offer these items on other old Honda forums. There is so little support for parts like these on the classic Hondas! Great work, that thing looks factory.

[2oodoor]

I was stuck in 'Quick Reply' for some reason. I had to exit out then go back in...

Yes there is something up with the reply templates.
I like this project Pete!

[Shawn87AccordDx]

Looks great!

[King Peetis]

if you ever wanted to make some extra money, you should offer these items on other old Honda forums. There is so little support for parts like these on the classic Hondas! Great work, that thing looks factory.

Thought about it a couple of times. I'm going to make what I need and a few others for the heck of it to hone my skills then I may offer up to some of the guys here first. If anyone needs the little clip I just made, holla. I'll make a couple of sets.

[King Peetis]

Yes there is something up with the reply templates.
I like this project Pete!

Next is that small T-handle on top of the panel in the cargo area. Pics soon.

[Stealth]

.

[redneck]

hell yea man thats pretty dope. ya can count me down for some even though i dont have a cover yet.

[King Peetis]

This is my first pour. Imperfections in the mold and lots of air bubbles. Did it in clear to check my skill.

http://img202.imageshack.us/img202/7062/firstpourcast.jpg (http://imageshack.us/photo/my-images/202/firstpourcast.jpg/)

Picked a resin that was too soft once cured. Same pour as the above photo.

http://img41.imageshack.us/img41/8627/toosoftresin.jpg (http://imageshack.us/photo/my-images/41/toosoftresin.jpg/)

Resin too hard and snapped when I tested it on the panel

http://img545.imageshack.us/img545/9037/toohardresin.jpg (http://imageshack.us/photo/my-images/545/toohardresin.jpg/)

[King Peetis]

Found this at the JY. First one I have ever seen intact

http://img577.imageshack.us/img577/1998/jythandle.jpg (http://imageshack.us/photo/my-images/577/jythandle.jpg/)


It is damaged from use and brittle from sun exposure but I can work with it

http://img820.imageshack.us/img820/908/thandle.jpg (http://imageshack.us/photo/my-images/820/thandle.jpg/)

Started freshening it up to prepare it to cast a mold

http://img842.imageshack.us/img842/2889/thandlerepair.jpg (http://imageshack.us/photo/my-images/842/thandlerepair.jpg/)

[King Peetis]

hell yea man thats pretty dope. ya can count me down for some even though i dont have a cover yet.

Right on RN, 'preciate it!!

[carotman]

Nice work!

The plastic clips that hold the outside trim around the rear windows on a hatch are impossible to find now. This could be one of your projects. I'd buy some for sure.

[King Peetis]

Nice work!

The plastic clips that hold the outside trim around the rear windows on a hatch are impossible to find now. This could be one of your projects. I'd buy some for sure.

Post up a pic of the part you're talking about. Any hatch related part, I'm down to make.

[Dr_Snooz]

Wow! That clip is bonkers! I couldn't tell the difference between the one you made and the original. You got skilz bro!

[2ndGenGuy]

DUDE! That is the coolest thing! Great work!

[cygnus x-1]

Great project! Is that a silicone mold your using?


C|

[King Peetis]

Great project! Is that a silicone mold your using?

Yea, it is. It's made by Alumilite. I got the kit at Hobby Lobby for $20.00

[thomson85]

Yea, it is. It's made by Alumilite. I got the kit at Hobby Lobby for $20.00

I would love to see a how to tutorial on casting molds. I think this is ingenious since such parts are hard to come by. I've thought about the use of 3D printers. But this seems more economical and practical.

[King Peetis]

My follow up on the T-handle; I think its done...

I got the t-handle glued to plastic board
http://img138.imageshack.us/img138/9510/thandleglued.jpg (http://imageshack.us/photo/my-images/138/thandleglued.jpg/)

Now Im building up a box to surround the part
http://img407.imageshack.us/img407/6237/glueingbox.jpg (http://imageshack.us/photo/my-images/407/glueingbox.jpg/)

Im ready to pour
http://img407.imageshack.us/img407/664/readytopour.jpg (http://imageshack.us/photo/my-images/407/readytopour.jpg/)

[King Peetis]

I forgot to include these pics. Once I got the part drilled off, I wanted to freshen it up a bit. I added epoxy where the plastic had become brittle and broken. then I added the grooves.
http://img10.imageshack.us/img10/292/20130105200746550.jpg (http://imageshack.us/photo/my-images/10/20130105200746550.jpg/)

I smothered it with scratch putty to hide as many of the imperfections as possible. I sanded it to give it a smooth finish.
http://img24.imageshack.us/img24/892/scratchputty.jpg (http://imageshack.us/photo/my-images/24/scratchputty.jpg/)

[King Peetis]

I poured the silicone over the part to make a female mold.
http://img16.imageshack.us/img16/239/framedmold.jpg (http://imageshack.us/photo/my-images/16/framedmold.jpg/)

Im ready to begin making a part
http://img845.imageshack.us/img845/6599/finishedmold.jpg (http://imageshack.us/photo/my-images/845/finishedmold.jpg/)

First run
http://img341.imageshack.us/img341/3071/pouringresin.jpg (http://imageshack.us/photo/my-images/341/pouringresin.jpg/)

http://img217.imageshack.us/img217/6056/pouredthandle.jpg (http://imageshack.us/photo/my-images/217/pouredthandle.jpg/)

[King Peetis]

After the resin set up, I pulled it from the mold.
http://img607.imageshack.us/img607/3412/20130114051206259.jpg (http://imageshack.us/photo/my-images/607/20130114051206259.jpg/)

I know it isnt perfect but it is as close as I can come to an OEM replacement part
http://img7.imageshack.us/img7/9716/20130115200243373.jpg (http://imageshack.us/photo/my-images/7/20130115200243373.jpg/)

[Dr_Snooz]

Looks awesome. The talent on this board never ceases to amaze me.

[cygnus x-1]

I've sent parts out for 3D printing, and the guy that does it also does silicone molding like this. The molded parts generally aren't as nice as 3D printed parts but they are quite a bit cheaper. Accurate 3D printing is still fairly expensive because of the materials used. It's really cool to see this molding process in action. I'll have to keep it mind for future projects.


C|

[King Peetis]

Looks awesome. The talent on this board never ceases to amaze me.

thanks Snooz! coming from you, that's a big complement!

[King Peetis]

I really need to learn how to use my electronics...

[King Peetis]

Resin casting is cool stuff. We have a couple of machines at work that I have been privileged to watch in action. I would guess the parts would be next to perfect built with CATIA and a laser. How much would a small part like that T-handle I made cost using 3D printing? just curious...

[carotman]

Post up a pic of the part you're talking about. Any hatch related part, I'm down to make.

I'll try to get a picture of some new parts I managed to find. I'm still missing some of the clips tough so I can only provide a schema.

Number 37 (Holds the top window trim)
Number 30, 33 and 39.
http://www.hondapartsdeals.com/hpa/images/illustration/31/1366348.png

[King Peetis]

I'll try to get a picture of some new parts I managed to find. I'm still missing some of the clips tough so I can only provide schema

Got it! I know what your talking about now. I have a hatch sitting in my driveway as a parts car. I will try to remove a clip intact and I will determine if I have the skill to make one.

[dacantu]

My goodness Pete, this is top notch!:thumbup:

[cygnus x-1]

Resin casting is cool stuff. We have a couple of machines at work that I have been privileged to watch in action. I would guess the parts would be next to perfect built with CATIA and a laser. How much would a small part like that T-handle I made cost using 3D printing? just curious...


Cost of 3D printed parts varies with material type and the process used, but I would estimate that plastic handle piece would probably cost $10-$20 or so. 3D printed parts are not always suitable for actual use though as the plastics are designed for rapid prototyping, not strength and long term durability. The rapid prototypes are good for making silicone molds though.

C|

[oldschool3g]

Wow man you and i need to team up and fabricate a new and improved 3g lol..love your work mad props

[carotman]

I managed to salvage some clips today! Are you willing to make some reproductions?

[Tdurr]

Omg, how did I not know you were doing this pete? We need to get some cup holders made haha