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Learning how to build Lotus Seven replicas...together!
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PostPosted: June 3, 2019, 8:20 am 
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Joined: October 19, 2012, 9:25 pm
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Location: Summerville, SC
as for the bender itself, you can buy the Eastwood tube bend for about $200. I can't build it for that.

10" CLR is a really odd sixe. That will drive your purchase price for the two hoops way up. You can always go with a 7" die and add some shoulders instead of a single bend.

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PostPosted: June 5, 2019, 3:32 am 
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Probably too early to estimate the under - over. I'm going to pour some tooling Urethane to try to make the surface of the 10" CLR die. The outside molds are pretty much done. The core needs to be machined yet, it's made out of various scraps of foam all glued together.

Wish me luck!


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PostPosted: June 6, 2019, 4:21 am 
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The under is looking better.

Foam core plug melted when I tried to fix a goof with Bondo. I don't know if it's some chemical or heat of cure that just melts the styrofoam. So I quickly formed (heh) a new plan to make the mold core out of 2x4s. That worked good.

After sanding the wood core, I covered it with carnuba auto wax and let it dry. I sprayed Universal Mold Release on everything and let that dry. Clamped the mold together.

Then I mixed the 10 lbs of mold urethane that only has a 6 minute pot life. It literally set up at about 8 minutes.

Sprung a leak because each half of the form molds distorted due to the weight of the Urethane. I was able to stop most of it with duct tape!

So about 1/2 hour later we got a very hot Urethane Die, ready to be finished. It's supposed to reach about 8,000 psi compression after 7 days.


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die_fresh.png
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PostPosted: June 10, 2019, 2:01 am 
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If this casting seems like it might work (50:50?), I'm gonna order steel to make the bender and reinforce the die. That'll be about $200, then the steel for the hoops is under $100.

I needed a break from stressing about the roll hoops so I got all the parts out of the basement and assembled it as much as I could.


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