metal smallframe / elestart "left" / battery door
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AmeriBodge
Joined: 01 Sep 2010
Posts: 266
Location: Undisclosed
Tue Apr 13, 2021 2:57 pm quote
so without revealing too much... I have the possibility of manufacturing (small batch) metal replacement battery-side doors for smallframes. likely 18ga or similar steel or stainless or aluminum.

I've connected with a local shop in NYC that does 3D scanning and I'm willing to invest in the tooling to stamp new pieces in the USA.

if these were priced at around $60 ea. would at least 10 people want one? that would cover my initial costs. I'm not asking for money up-front, just gauging if anyone would want one. when I looked into doing this a couple of years ago there wasn't much interest, but prices have since come down significantly and this is a lot less expensive to do.

I know there are some out there made of fiberglass but a lot of prep work has to go into making them look presentable. these would look basically identical to the originals and could be painted with minimal prep work (or chrome plated or whatever).
bodgemaster
63 GL, 76 Super (x 2), 74 Primavera (x 2), 06 Fly 150
Joined: 26 Sep 2013
Posts: 5830
Location: So Cal
Tue Apr 13, 2021 3:16 pm quote
Put me down for one, maybe two.
Hooked
'80 Bajaj Chetak; '65 Vespa V90; '59 Lambretta Li125
Joined: 10 Feb 2008
Posts: 492
Location: St. Louis, MO
Tue Apr 13, 2021 4:12 pm quote
I would be in for one, yes please.
Member
66 bluebadge,primavera,2x 74 rally,79 p200e 64 gl 2x 64 vbb 2x ld 57 ld 125
Joined: 08 Dec 2014
Posts: 37

Tue Apr 13, 2021 4:17 pm quote
Put me in for one.Please
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AmeriBodge
Joined: 01 Sep 2010
Posts: 266
Location: Undisclosed
Tue Apr 13, 2021 4:42 pm quote
Help me collect contact info for when this happens: fill out this form! https://forms.gle/sX428E7mk14VPRHr6

Need to source a good non-damaged panel first (waiting on responses from a few people).

Already have the manufacturing process lined up and ready to go...

Only thing these won't include is a latch (some may opt for a lock or pins or something).
Member
1974 Primavera
Joined: 16 Aug 2020
Posts: 14
Location: St george ut
Tue Apr 13, 2021 9:00 pm quote
plsssss
id definitely buy one
Style Maven
74 50s x3 78 P200 x2 84 Cosa PK50XL2 58 AllState 68 Sprint 80 50special '66(?) Super125
Joined: 22 Nov 2010
Posts: 8156
Location: seattle/athens
Tue Apr 13, 2021 9:11 pm quote
V oodoo wrote:
saturn wrote:
I'm having repros stamped. See my thread! metal smallframe / elestart "left" / battery door

Voodoo do you want to loan me yours to make the tooling?
Aw HELL yeah! It's about time and casting them looks like would likely be more dough anyway in small lots and minimal tooling.

Pm me your phone number, Ace!
Addicted
Too Many piles of Junk that need too much work and too much money
Joined: 06 May 2019
Posts: 628
Location: Roseburg, Oregon
Wed Apr 14, 2021 12:06 am quote
Count me in for one. I'd think $60 is more than reasonable for short run. If you need an NOS original to scan, I may be able to help. PM me.
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AmeriBodge
Joined: 01 Sep 2010
Posts: 266
Location: Undisclosed
Tue Apr 27, 2021 11:40 am quote
Update:

NOS panel is in the 3D scanner and I'll have a 3D model soon. Once I have a good model I can make molds and start stamping.

Addicted
Too Many piles of Junk that need too much work and too much money
Joined: 06 May 2019
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Location: Roseburg, Oregon
Tue Apr 27, 2021 12:11 pm quote
Very exciting!
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AmeriBodge
Joined: 01 Sep 2010
Posts: 266
Location: Undisclosed
Tue May 04, 2021 9:54 am quote
it's happening!



Addicted
Too Many piles of Junk that need too much work and too much money
Joined: 06 May 2019
Posts: 628
Location: Roseburg, Oregon
Tue May 04, 2021 12:34 pm quote
Now thats Progress!
Style Maven
74 50s x3 78 P200 x2 84 Cosa PK50XL2 58 AllState 68 Sprint 80 50special '66(?) Super125
Joined: 22 Nov 2010
Posts: 8156
Location: seattle/athens
Tue May 04, 2021 1:25 pm quote
At long last
Nice one, Andrew!

American Smallieists rejoice!
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AmeriBodge
Joined: 01 Sep 2010
Posts: 266
Location: Undisclosed
Tue May 04, 2021 2:25 pm quote
just waiting on some tooling to arrive (Thursday??) and need to build the mold and do some test stamps

what we'll end up doing is offering to do hinges for people (steel, brazed/spot welded in place) but do a center point dimple where the lock should ideally go (leaving the area blank for options of factory latches or mailbox latches, dzus fasteners, etc - different hole sizes)

will also be doing stamps in different gauges of steel and aluminum to see what works best, and my guess is a light gauge steel will be best

as you all know, many repop panels are thinner for cost saving - and the same applies here obviously - but thinner gauge is also easier to stamp!

I hope for the price point this is acceptable to everyone

will update when I have more news/photos
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AmeriBodge
Joined: 01 Sep 2010
Posts: 266
Location: Undisclosed
Tue May 04, 2021 2:59 pm quote
also (just for fun) here's a view of how detailed the 3D scanner can get: it was able to pick up the texture of the factory sticker on the NOS panel.



Addicted
Too Many piles of Junk that need too much work and too much money
Joined: 06 May 2019
Posts: 628
Location: Roseburg, Oregon
Tue May 04, 2021 6:21 pm quote
Very cool! Thanks for sharing the scans, and plans. Nice detail!

I understand the necessity to use lighter gauge steel, for easier stamping. However, I would personally lean more toward a heavier gauge, even if it means a slightly higher price point. If I had the choice between a cheaper light panel, and a more expensive heavier (stockish gauge) panel, I'd gladly pay for the later. Although that is just me. There are limitations, so something better than nothin I dont think a lighter panel would be an issue, as long as it wont get dented by the wind blowing. Just my 1.5 cents.

Dimple for lock position is a great plan!

You obviously have thought this through, so keep up the good work!
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AmeriBodge
Joined: 01 Sep 2010
Posts: 266
Location: Undisclosed
Tue May 04, 2021 6:56 pm quote
even 24ga steel (0.024" - probably thinner than I'll go) is going to be pretty good and sturdy once pressed - this panel has a very long arch and a curve at the end for rigidity

for comparison, most kitchen sinks are 18-22ga stainless and pretty much bulletproof

it just depends what the press can handle, which I'll know soon
Addicted
Too Many piles of Junk that need too much work and too much money
Joined: 06 May 2019
Posts: 628
Location: Roseburg, Oregon
Tue May 04, 2021 7:17 pm quote
saturn wrote:
even 24ga steel (0.024" - probably thinner than I'll go) is going to be pretty good and sturdy once pressed - this panel has a very long arch and a curve at the end for rigidity

for comparison, most kitchen sinks are 18-22ga stainless and pretty much bulletproof

it just depends what the press can handle, which I'll know soon
See, you have thought this through well Carry on!
Enthusiast
Rally 180, TS 125, PX 150 and a lot of smallies
Joined: 19 Oct 2013
Posts: 92
Location: Paso
Tue May 04, 2021 8:06 pm quote
Very excited. I can finish my small frame.
Style Maven
74 50s x3 78 P200 x2 84 Cosa PK50XL2 58 AllState 68 Sprint 80 50special '66(?) Super125
Joined: 22 Nov 2010
Posts: 8156
Location: seattle/athens
Wed May 05, 2021 7:25 am quote
Scan detail is impressive! Can you share more info on the scanner please?
Hooked
AmeriBodge
Joined: 01 Sep 2010
Posts: 266
Location: Undisclosed
Wed May 05, 2021 8:03 am quote
I'm not an expert on it (I don't do the scanning myself), but my understanding is it uses lasers as probes to translate basically a radar-type reading into a 3D image with incredible precision.

That raw image is then manually processed in a CAD program to create a more smooth surface.

In this case, we didn't make it perfectly smooth, as the original molded part was done by hand before computer design, so it wasn't "perfect" to begin with. Also, the mold's details will be "averaged" when the steel is pressed against it, so you won't see them anyway (these sorts of details would only be visible in a direct 3D print or CNC part).

Attached is the raw scan (latches and imperfections and all) vs. finished "smoothed" panel model.

More info: https://www.cubodesigns.com/3d-scanning





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