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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: curt ()
Date: June 01, 2016 08:05AM

WOW, great

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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: SteveH ()
Date: June 01, 2016 09:04AM

Dave - First this looks fantastic. I do a lot of metal casting and boy howdy, those are some of the smoothest looking molds I've seen... just wow.

What is the benefit/difference between a vacuum chamber vs a pressure chamber in the mold Making process?

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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: Spectre ()
Date: June 01, 2016 10:03AM

very impressive!

David Clamp


1965 Corsa convertible - 140 4spd/3.55/AM-FM

2013 Mustang GT convertible - 5.0, 6spd auto, Procharger i-1

2003 Miata SE - 6spd manual (wife's toy)

"Victory is mine!" - SG

Warner Robins, GA (15 miles south of Macon)

Click for Warner Robins, GeorgiaForecast


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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: azdave ()
Date: June 01, 2016 12:15PM

SteveH Wrote:
-------------------------------------------------------
> Dave - First this looks fantastic. I do a lot of
> metal casting and boy howdy, those are some of the
> smoothest looking molds I've seen... just wow.
>
> What is the benefit/difference between a vacuum
> chamber vs a pressure chamber in the mold Making
> process?

Thanks. A pressure chamber is not as critical to use when you make molds but it is a "must have" for casting flawless clear parts.

I use both vacuum and pressure chambers. The liquids used for both the molds and the lenses are viscous enough that getting trapped air out of them after mixing is a real challenge, even more so when the casting epoxy is crystal-clear and shows every flaw in the finished product. You have a short pot life to get things done so you can't afford to wait for the bubbles to rise to the top.

Two to three minutes of vacuum degassing expands the majority of the trapped air enough that it floats to the top and bursts. For mold making, you can usually pour very slowly after de-gassing and simply let it cure. Putting it in a pressure chamber is not mandatory but if you are pressure casting the final parts then submitting the mold to the same pressures is a good practice.

For making the actual part (and especially with see-through resins), there will always be some air bubbles remaining in the mix or sometimes accidentally caused during the mold filling process. If you quickly place the filled mold into a pressure chamber before it gels up you can compress the remaining air bubbles so small that they are not noticed. You then have to let it cure while still under pressure.

Again, if you pressure cast your final parts then the experts generally recommend to cure the molds under the same pressure conditions. If you don't cure the molds under pressure then hidden air bubbles in the mold could collapse under the casting process pressure and actually cause some "acne" like defects on the surface of the final parts.

If I were making fully opaque parts I could skip all the pressure chamber work entirely.

For a vacuum chamber, I use several sizes of very thick-walled cooking pots with a 1/2" thick Plexiglas lid and custom gasket. The silicones and epoxies boil and expand about 3 times in volume as the gas escapes and you need to be able to see it as it degasses so that you can modulate the vacuum and prevent a wasteful overflow.


For a pressure pot, I converted a Harbor Freight paint pot. I am lucky that these lenses will fit inside that pot as buying larger pressure chambers is expensive and no way do I want the danger of building my own. I use 60 PSI and have a dedicated regulator and safety relief valve on the pressure pot.


Dave W. / Gilbert Arizona
66 Corsa 140 4-speed w/factory A/C
66 Corsa 140 4-speed w/factory A/C
66 Corsa 140 4-speed
65 Corsa 140 4-speed
66 Corsa 455 Toronado V8
65 Monza 455 Toronado V8
65 Monza 4DR 140 PG w/factory A/C
65 Monza 4DR EJ20T w/5-speed


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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: SteveH ()
Date: June 01, 2016 04:46PM

so, to be clear, the main difference is speed of the function or the method?

Speed, in that the vacuum takes too long

or

The compressing of the bubbles vs trying to "extract" them

CORSA Member #034095
SF Bay Area zip:94580

1965 Corvair Corsa "Field Find" 140hp 4speed
Built 9/15/64 #148 off the LOS line, #1448 for the year
1965 Corvair Corsa "Corsamatic" 140hp PG

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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: azdave ()
Date: June 02, 2016 09:00AM

SteveH Wrote:
-------------------------------------------------------
> so, to be clear, the main difference is speed of
> the function or the method?
>
> Speed, in that the vacuum takes too long
>
> or
>
> The compressing of the bubbles vs trying to
> "extract" them

Except for crystal clear parts, if you are using low viscosity materials that pour very easily and also cure very slowly, then neither vacuum or pressure methods are really required to make nice molds or parts.

With any materials that have a short pot life and/or pour like molasses on a cold day, you'll want to use vacuum and/or pressure in the process to expedite getting rid of any trapped air.

When it comes to making crystal clear parts, even with the lowest viscosity resin and the longest pot life available, you still need a pressure pot to fully hide all the bubbles.


Dave W. / Gilbert Arizona
66 Corsa 140 4-speed w/factory A/C
66 Corsa 140 4-speed w/factory A/C
66 Corsa 140 4-speed
65 Corsa 140 4-speed
66 Corsa 455 Toronado V8
65 Monza 455 Toronado V8
65 Monza 4DR 140 PG w/factory A/C
65 Monza 4DR EJ20T w/5-speed


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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: quorvair ()
Date: June 05, 2016 05:32AM

Dave, you have amazing talents..!!

Thanks for sharing all that knowledge...!!!

Daniel Vallée
1965 Monza Convertible 140PG
1961 Rampside 140PG
Salaberry-de-Valleyfield, Québec, CANADA

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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: Darrin ()
Date: June 05, 2016 06:03AM

Awesome. Admire your skills and meticulous approach. Respect.

Darrin Hartzler
Bethesda, MD

Corvairs in two states of the Union and varying states of disarray.

Northern Virginia Corvairs & Group Corvair

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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: azdave ()
Date: June 15, 2016 06:23AM

Slow progress recently on the lens project due to other life adventures but I'm still at it. I spent most of the last week helping friends empty the house of a hoarder. That was an adventure! I'm off to China in a few days and when I get back I'll have relatives in town through early July.

Update:
So when I sell these clear directional lenses, I want the buyers to use new, soft gaskets instead of re-using old, nasty ones. I figured the best way to ensure that would be to include a new pair of gaskets with each set sold. Done.

I'm still experimenting with casting several different water-clear epoxies. Some will be getting some real heat stress testing this weekend. It might hit 119-120F on Sunday and I'll have lenses mounted in housings out in the sun all day so I can look for any issues when I return from China.


Dave W. / Gilbert Arizona
66 Corsa 140 4-speed w/factory A/C
66 Corsa 140 4-speed w/factory A/C
66 Corsa 140 4-speed
65 Corsa 140 4-speed
66 Corsa 455 Toronado V8
65 Monza 455 Toronado V8
65 Monza 4DR 140 PG w/factory A/C
65 Monza 4DR EJ20T w/5-speed


Attachments:
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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: coleslaw31 ()
Date: June 15, 2016 06:38AM

You are the man. Sign me up on the list!

South Carolina Upstate



68 Monza convertible 140 4spd A/C (coming soon)
66 Corsa coupe 140 4spd

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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: texas yenko dude ()
Date: June 15, 2016 07:07AM

They look great and I am glad you are tackling this project. Someone 5-10 years ago did this as well. i dont remember who, but I bought a pair from him. I still have them on the shelf. I plan on putting them in my 66 180 coupe. I would love another pair or 2 for the 69's

Texas YENKO Dude
YS-070
YS-199
YS-320
Southeast of Disorder


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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: art in va ()
Date: June 15, 2016 07:03PM

Put me down for a pair when they're available. I'll keep an eye out.

Art in VA
67 Sedan

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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: matchlessmo ()
Date: June 18, 2016 04:58AM

Sir, add me to the list.....


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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: 66vairman ()
Date: June 18, 2016 08:25AM

Great work Azdave.

A number of years ago I found a picture with a car where the owner had made up clear lenses and the white gasket really stood out like I see in your pictures. Just me but I don't find it attractive.

I was wondering if the Euro clear lenses GM used had a little white pigment to make them a little opaque, or give them a frosted look like I've seen on NOS early 60's Chevy front lenses?

Another solution would be to paint the inside of the turn signal housing white with high temperature paint. I've done this on my rear tail light housings and it makes the tail lights brighter.



Edited 1 time(s). Last edit at 06/18/2016 08:29AM by 66vairman.

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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: coleslaw31 ()
Date: June 18, 2016 08:30AM

I saw somewhere that a gray gasket was put on with the clear lenses. It was a swiss car the thread was about.

South Carolina Upstate



68 Monza convertible 140 4spd A/C (coming soon)
66 Corsa coupe 140 4spd

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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: Paulsgt ()
Date: June 18, 2016 09:21AM

I'd be in on that too Dave! Those are awesome!

Paul Sergeant
CORSA Central Division Director / CORSA Treasurer <-new title
Lee's Summit, MO
CORSA since 1975
Member – HACOA, Corvair Minnesota, CORSA, Little Indians, POCI



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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: American Mel ()
Date: June 18, 2016 11:01AM

coleslaw31 Wrote:
-------------------------------------------------------
> I saw somewhere that a gray gasket was put on with
> the clear lenses. It was a swiss car the thread
> was about.


Just my humble opinion, but I think this sounds like a good approach.thumbs up
The pure white gasket sticks out like a sore thumb.thumbs down
BUT, that being said, it looks MUCH better than a grundgy dirty old gasket!
.
Would it still seal properly if it had a thin Mylar type "chrome" coating on the gasket?
Just a thought. Any other ideas?
.
I will still take a set either way. Those are just too cool!
I want to run switch-back LEDs with amber blinkers and clear running lights.cool smiley

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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: azdave ()
Date: August 02, 2016 03:04PM

Update:

I haven't forgot about this project! After my China trip I returned sick and missed a week of work and then two days later my father passed away and I spent the next week in Indianapolis with my mom and family. Since then I've been catching up after what feels like missing a whole month of work at both home and on the job. This Thursday I'm having my left hand operated on like they did to the right hand in late April so it's back to being temporarily out of commission again. Argh! My right hand has recovered well so I want to do the left hand but the right elbow procedure is another story.

I did have time to test the "gasket coloring" question that was posed by some and it does have a little benefit to the cosmetics. After the lenses are installed and viewed in the normal location below the bumper, I feel the difference is not as noticeable.

I painted several gaskets with various color spray paints and while none adhered aggressively to the flexible foam it does work well enough to serve the purpose. SEM vinyl spray worked the best but I think anything you have would be okay. I won't be going to the trouble of buying the foam already colored as that is too expensive. I'll let my customers paint their white foam gaskets if they wish. I'll have some pics of the colored gaskets added to the thread soon.

Still not selling these quite yet but on schedule for a late summer release.


Dave W. / Gilbert Arizona
66 Corsa 140 4-speed w/factory A/C
66 Corsa 140 4-speed w/factory A/C
66 Corsa 140 4-speed
65 Corsa 140 4-speed
66 Corsa 455 Toronado V8
65 Monza 455 Toronado V8
65 Monza 4DR 140 PG w/factory A/C
65 Monza 4DR EJ20T w/5-speed


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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: MattNall ()
Date: August 02, 2016 03:23PM

Good!! 'cause someone here has found the perfect bulb for them!!.... Although you'll come up with something better .... I'm sure!





MODERATOR
Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
Click HERE for My Website...Click HERE for My TechPages!
..............................110-PG.................................................Webered-Turbo

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Re: Creating Clear LM Front Turn Signal Directional Lenses
Posted by: jjohnsonjo ()
Date: August 02, 2016 04:58PM

Geeze Dave, really sorry to here about your Dad, and the rest of what life can dish out. Matt and I were just having a quick chat about how amber/white switch backs would work with your lenses.

Like this for those who don't know what they are.

[www.amazon.com]

These are more $$ than some, but have real good reviews. I think they would really rule on a Vair, BRIGHT DRL that become bright turn lamps.

J.O.

65 Corsa Turbo Vert
79 Honda XL 500S
69 Honda CL 160 D
2010 BMW F 650 GS
2003 Bounder 36D
2013 KIA Optima SX turbo-AKA ZIPPY (wife,s car)
69 Newport Holiday Sailboat
Baja 150 dune buggy cart
Coleman HS 500 UTV
2016 KIA Sorento SXL Turbo

Bethlehem,Pa

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