Modern Vespa

Hi folks. Anyone have any experience with 3D printer shops? I want to make a custom part (or two) for my Rally and want to make it out of aluminum or something similar that will take a good polish or chrome. Any advice? Thanks!

3-D printing isn't really to the point yet where you can spit out an aluminum part, at least in anything outside of a proof-of-concept laboratory setting.

depending on the part, there are other ways to have it manufactured, from 3-D printing in wax to do a casting to 5-axis machining.

however, any way you look at it, cost may be prohibitive. when I designed and had manufactured a performance reed manifold for LML cases, the cost was mind-bogggling untill i found someone willing to do a small batch of 20 of them in China. even then, it came out to be a few hundred per.

I have a buddy that owns a tool and die/machine shop business that's turned out some amazing items over the years for my bikes and race car for a case of cold beer on ice and a good take out burger and fries. Sounds as if you need to warm up to someone with a machine shop? The down side, he works at his own pace and his wife seldom lets him out after dark, but he does like beer and a good greasy burger due to his wife being a health fanatic. Everyone has a motivator.

Thanks for the news. I figured it might cost a bit but wanted to get some advice. I'm trying to keep my 74 Rally intact with the turn signals holes in the cowls but want better looking turn signals there, in the stock holes. I hope to find the stalks, without the turn signals that attach to them, that reside there and modify a pair of them to work, at the very least. Having a bit of trouble even finding the orig turn signals themselves. Have a great day and thanks for the response.

Willie, give me his name and I'll send him two cases of beer and 75 bucks worth of Ruby's Diner Gift cards, ha ha!

Good advice though, thanks.

the problem is that unless your design matches their capabilities it's kinda useless. for my design i needed a 5-axis CNC machine, or days worth of setup between operations on a 3 axis. unless it's a fairly simple part the cost gets high unless you have a contact with a very high-end, well equipt machine shop. and the guys with $100,000 machines tend to be super scheduled to take advantage of every minute of machine time and not good ol' boys willing to work for beer.

really it depends on the part. simple flat things? easy. compound curves, overlapping edges, etc... pricey.

what do yo want to make?

If you go for painted instead of chrome you could 3D print in nylon.

I've had a bunch of parts done at shapeways and the "Strong & Flexible" material is really useful and affordable. If the walls are ~2mm it gets quite strong.

http://www.shapeways.com/materials/strong-and-flexible-plastic
http://www.shapeways.com/shops/oopsclunkthud

As a printer who also has his own press on the side, 3d printing has really caught my eye. Especially since I do my own repairs and maintenance of everything I own, parts are a real pain in the ass to come by at times (nevermind the future of "printing"!). So this post caught my eye and I remembered reading a story about resin molds to cast alloy metals in to customize this dude's muscle car. I couldn't find the original article but here is one better:

http://hackaday.com/2012/09/25/turning-3d-prints-into-aluminum-castings/

Happy printing/riding!

I'm looking to fashion a signal that follow the contours of the cowls and uses the existing rubber gasket. I wanted to use three yellow leds on a small circuit board inside the signal, 6v of course. The design is somewhat simple but, it will need to have some serious curve on the bottom to follow the shape of the cowl. If I can't do that, I will try and get a pair of the signals stalks, modify them to make them shorter and accept a smaller light.

You make a lot of good points Rob, thanks.

Thanks Mathew, looks like as great place to start! Thank you as well oops, great name btw!

honestly, something has simple as that i would say go to the local motorcycle shop and look thru the parts unlimited catalog. there are a lot of options close to that in there.

also keep in mind; you'll need to have lenses made if you go custom and that gets even more complicated.

I created a 3D model of the turn signal housing that I want to get 3D printed to see if it would work and check the fit. Then have them machined out of aluminum.

i have to ask, is there a reason you're going custom rather than off-the shelf?

there are standard assemblies available that are pretty much identical to that.

In theory this sounds good, but he prefers to drink beer and smoke cigars with someone while working when no one else is around his shop. I don't abuse the privilege, but it's always there when needed. I also return the favor by sending someone to perform repairs on his home and building when the need arises. I've known him for years from our early autocross days. He had a Corsa Corvair that was unbeatable. From there we both got into formula Vees for a while, then life, children and spouses came along and curtailed both of our extracurricular activities.

The off the shelf ones don't quite look like the originals and the originals are plastic. Plus I wanted to have something unique.

[quote="rob hodge"] the problem is that unless your design matches their capabilities it's kinda useless. for my design i needed a 5-axis CNC machine, or days worth of setup between operations on a 3 axis. unless it's a fairly simple part the cost gets high unless you have a contact with a very high-end, well equipt machine shop. and the guys with $100,000 machines tend to be super scheduled to take advantage of every minute of machine time and not good ol' boys willing to work for beer.


really it depends on the part. simple flat things? easy. compound curves, overlapping edges, etc... pricey.

Considering my friend has a business that supports most of the automotive manufacturing businesses in the area, he is very capable of making anything coming and going. His shop runs 24-7 at times depending on demand. If TMM (Toyota) or the local glass manufacturing company has a machine go down, they don't send everyone home, but they urgently call him and his business springs into action. Even though he has numerous employees and some pretty scosche looking machines, under his professional appearance he's still the beer drinking redneck I've known for years, not a low jeaned, crack bearing too small t-shirt wearing fool. Sorry if I gave you the wrong impression. They do have a shop dog.

then you definitely have the exception, rather than the rule. i'd definitely take advantage of that.

Really great responses here, thanks guys. I was just joking about using your guy Willie, but what a great resource you have there, and the shop dog cinches the deal for sure!

Lots of things to think about but I believe others were curious as well. Much appreciated!

A really great machinist once told me, "never make what you can buy." I make/have made a lot of stuff but I always stop and consider if someone makes it already.

If I was looking for nice looking lights to fill the holes on a Rally I think I'd give these a try.
http://www.sip-scootershop.com/en/products/indicator+lens+kit+side+panel+_j57056000

Hmm, those aren't that bad looking. I wish they showed the bottom to see how they attach. Thanks for the tip though. You like SIP stuff?

Here's underneath...


I've made a few things with Shapeways. Check out their materials section to get an idea of what can be done. Their metals are made with metal dust and binders, although you wouldn't know to look at it.
Have a look, if you see a material you think you can use, let me know and I'll build you a 3-D model. Then it can be uploaded and priced. No charge from me, I love that stuff.

Thanks for that picture! My Idea is really pretty simple and can probably be made with those materials. I'll definitely give it a look, thanks again.