This tech. would make an awesome skylight!!! Could you build your oven larger to accommodate say 12' - 16' foot polycarbonate domes? This could be a revolution in the building & agricultural industry...
FYI- You can buy coiled nichrome wire for heating air. 5kw, 10kw, 15kw, and 20kw. Then buy ceramic donut insulators to support the coiled elements. 220 volts
Or easily produced aerogel can be used, it's the stuff that allowed the space shuttle to survive landing back on the planet without even so much as a singed hair even. Rock on. #TheDigitalLifeguardProject-_-
this is absolutely awesome. I bought some lexan to make a dust collector for a shop-vac and I've been researching how to thermoform the lexan to the specific shape I want. this video answered all of my questions. thank you so much
How much did it cost to build the oven itself? I would love to build a larger oven to make larger parts but I worry that construction costs of the oven could get out of hand.
I love your drive man, I came here looking for a way to just lay a piece of polycarbonate over my windshield and heat it to form a replica. You sir have ensured there will not be a time when get an idea and think its out of my league =)
fantastic information...thank you so much for doing the hard work......very clever man.......I'm just researching the practicalities of an idea I've had for a roofed motorcycle......thank you so much..
Blow forming would not give the repetitive accuracy/tolerance you would require for a project like this. Just a tiny variance in the pressure, temperature or the thickness of the material would result in a different shape. You need to vac form over a former so that every canopy formed is identical and the variables are eliminated.
Been considering using similar idea to make a motorcycle fairing (likely 'dustbin' style) that is transparent, so you can still see the engine & suspension.
Now that you've got this setup, I wish you'd run up a bunch of headlight covers for 1966 to 1993 Alfa Romeo Spiders. The clear plastic covers made by Carello are both expensive, and tend to warp/shrink. I'd buy a pair!
The video you referenced shows acrylic sheet being being molded. It's very likely that it is getting scratched and will need polishing. Polycarbonate can't be polished, so free-form blow molding is the only option if the surface is to remain optically unblemished.
He went to town on that project and determined to achieve desired results, and that apparently cost him some serious coin. You can learn from the process shared as it achieved his goals, and you can replicate such goals on a smidgen of the cost, that is my goal anyhow lol. Keep on rocking as you roll in the creative dept.
I am wanting to form a replacement wind shield for my motorcycle , out of .250 plexiglass.I need to heat it to 360 degrees and let it lay down on a form I'm going to make from the old wind shield that they don't make any more . You are the only person I have found that seams to know what they are talking about so my question is, what can I cover my formwith that will take the heat and not mess up the clarity of the finished windshield . I worked for a man years ago and helped him build and oven to blow form a window for a medical helicopter but I did not remember the temperature or what we put over the forms.Can you help me please.
you could possibly go into business blowing bubbles for custom cars. He he I did the same thing with camp stoves and a large OSB box and made a bubble for my 3 wheeled motorcycle.
+James Armstrong Ha ha. I've had 2 Vanagons in the past and currently have a 1991 mercedes 300D 2.5 exactly like the one on the vid. I also had a neighbor with a Volvo 850 Wagon the same color as the one in the vid. I was thinking this garage looks very familiar. Cool Cars and even cooler electric car concept! I'd love an update!!!
Great job Gary! ...but three videos in seven years makes me think your dreams never came to fruition. How's it going dude? Gotta give kudos to the dreamers that do... If you opened a bakery instead I'm going to be seriously disappointed.
I could be wrong but is it seems like the cart is coming before the horse, what about the drive system, suspension and interior? Those are all key elements that generally drive exterior packaging.
Thank You so much. I have many questions that what you have showed, may be or in part is what I have been searching for. I will gladly pay for your help.. I will soon email you. Thanks again.
Oh my god, you just made my day. I Have been looking at the best way to form back glass for my p.u. I used to see these types of windows alot back in the early to mid 80's but have not found any info as of late. thanks for the great video.
a while back when i was working for a job shop we built a oven that was 4'x8'x8' to heat up acrylic 1/2" acrylic sheets. we used one industrial covection oven as the heat source.
Was the room necessary? This seems similar to vacuum forming. Couldn't you use some heating elements above the plastic, and once it sags add air? Is there some piece of knowledge I am missing?
You are pretty smart and that's badass but why use fiberglass insulation when polyurethane is like 80% more efficient. I bet your shop was warm during 4 ovens operation. Polyurethane doesn't burn at the temps ur using those 2x4s would be the weakest link. Experiment with the poly you'll love it
It is that really 350 Degrees? I have tried to do the same and policarbonate always bubble like and alka-seltzer!! very disturbing quality . that make me quit using poly-carbonate! Never the less this was a very nice video, I meant it. thank you very much.
+Migueldeservantes You have to dry polycarbonate before putting high heat to it. We usually dry at 140 deg for 4-5 hours. After that you can heat it until it sags to the floor and it won't bubble.
+Joe Fox WOW !!! Your answer mean the world to me thank your so very much for answering, every one in the sign industry was telling me that it have to be done under a high pressure to avoid the bubbles. It is there any tell tell sign that it is ready for high heat??
+Migueldeservantes People in the sign industry want to do the work themselves. What causes the bubbles is moisture in the plastic. Most plastics are hydroscopic. When you heat the plastic without drying it the moisture expands and turns to steam making bubbles. Slowly heating it at a low temp for several hours cooks the moisture out without bubbling. We use quartz heating tubes on our thermoformers and if were running sheets that haven't been dried we will heat the sheet very slowly for about 45 minutes then put medium heat to it for 20 minutes then finally bring it up to forming temp in the last 5 minutes for about a 1 hour cycle. If the sheets have been dried we can heat a 1/4" sheet in about 6 minutes under high heat.
You know that one think about most polymers as as very solid material that can eve use as a moisture barrier!! but I guess that once "One have been working for long enough with this type of plastics.. one start to learn about it. Thank you again and again!
thanks for the clip.......is the polycarbonate sheet need to preheat before the operation?i formed like this but make some buble inthe part after blowing....
Hi Gary, Thank you for the excellent video! We are a sculpture studio that is experimenting with thermo forming. We have been using acrylic, as we understand it is more UV resistant, and will be likely to yellow over time. The drawback of using acrylic, is that it becomes very brittle after forming, and is difficult to trim without breaking. My question is if we use poly-carbonate which is less brittle, can we expect yellowing over time, or is this a UV stable solution? Thank you again.
Does the depth of the box built for blow forming have an effect on the outcome, or would it not matter if there was only a 1" void underneath the poly sheet, as long as pressure was built slowly and evenly?
+Kevin Ford it shouldn't matter at all, unless maybe the air flow into the box is such that it blows onto the hot plastic, causing deformation and local temp changes. Some sort of baffle / diffuser setup should prevent that.
lower box would be susceptible to warping as rigidity is reduced. If only 3lbs is applied it could be made from thinner steel instead of the heavy gauge beams shown here.
Jerry Roane We hold these truths to be sacred & undeniable; that all men are created equal & independent, that from that equal creation they derive rights inherent & inalienable, among which are the preservation of life, & liberty, & the pursuit of happiness; ...
I clicked thumbs up as soon as he said I knew it would work and then bought 4 ovens.
hahaha you should check out love and saucers, a documentary about a kindred spirit of this video's protagonist.
Videos like this make me love youtube
I love 2:47, dog gets a slap by the sound of it lol
Nice - any update on the full scale blow forming?
you Sir are a champion, thanks for the video. great to see people still share creative knowledge in the way that you did.
Hi Gary, I thought PolyCarb when you heat it enough to bend it bubbles due to moisture in air, how did you avoid that?
Moisture inside the plastic..You have to pre-heat the polycarb for 24 hours at 100 deg C before attempting to form it.
fantastic! i love the analyzing and thought processes that go into these/////All Things.
nice work. cant wait to see next vids!
This tech. would make an awesome skylight!!!
Could you build your oven larger to accommodate say 12' - 16' foot polycarbonate domes? This could be a revolution in the building & agricultural industry...
FYI- You can buy coiled nichrome wire for heating air. 5kw, 10kw, 15kw, and 20kw. Then buy ceramic donut insulators to support the coiled elements. 220 volts
I bought four brand new ovens... giggle
Or easily produced aerogel can be used, it's the stuff that allowed the space shuttle to survive landing back on the planet without even so much as a singed hair even.
Rock on.
#TheDigitalLifeguardProject-_-
this is absolutely awesome. I bought some lexan to make a dust collector for a shop-vac and I've been researching how to thermoform the lexan to the specific shape I want. this video answered all of my questions. thank you so much
super job gary send you my trike link A1 cargo trike
How much did it cost to build the oven itself? I would love to build a larger oven to make larger parts but I worry that construction costs of the oven could get out of hand.
I love your drive man, I came here looking for a way to just lay a piece of polycarbonate over my windshield and heat it to form a replica. You sir have ensured there will not be a time when get an idea and think its out of my league =)
Any Update? looks amazing!
fantastic information...thank you so much for doing the hard work......very clever man.......I'm just researching the practicalities of an idea I've had for a roofed motorcycle......thank you so much..
Outstanding! Thank you very much.
I would recommend you use nitrogen to fill the oven to prevent crazing over time
Great way to set your house on fire. Good job.
Blow forming would not give the repetitive accuracy/tolerance you would require for a project like this. Just a tiny variance in the pressure, temperature or the thickness of the material would result in a different shape. You need to vac form over a former so that every canopy formed is identical and the variables are eliminated.
Do you make the bubble canopy for sale
Been considering using similar idea to make a motorcycle fairing (likely 'dustbin' style) that is transparent, so you can still see the engine & suspension.
couldn't you just aim infrared lamps at the poly instead of making a big oven? You could use a temp gun to verify even heating.
With only 3lbs of pressure the pressure enclosure might be made from way lighter gauge steel, but i guess that doesn't matter much.
Now that you've got this setup, I wish you'd run up a bunch of headlight covers for 1966 to 1993 Alfa Romeo Spiders.
The clear plastic covers made by Carello are both expensive, and tend to warp/shrink.
I'd buy a pair!
Hey. Randomly read your post. I can try to make polycarbonate covers for you if you have samples.
this is mindblowing, could you tell me where I could buy one in the sice of a bigger person as a safe sleepingplace....
I must give you A+ for the project. Great job sir.
What ever happened to this project? Guy must have died.
Check out this:
ua-cam.com/video/VlzfPzQXACY/v-deo.html
The video you referenced shows acrylic sheet being being molded. It's very likely that it is getting scratched and will need polishing. Polycarbonate can't be polished, so free-form blow molding is the only option if the surface is to remain optically unblemished.
Absolute informative! Good luck with you car. Magic Mike 719
poly carbonate only last 5 years in the sun, i would not recomend it for this purpose
Holly vacuum, that's awesome. Gives me hope.
Vacuum heating supported table
Brilliant! (Also love the caravelle/vanagon at 00:47)
That is an awesome blow mold set up! Well done!
Thank you for this genius informations.
What an amazing build.
He went to town on that project and determined to achieve desired results, and that apparently cost him some serious coin.
You can learn from the process shared as it achieved his goals, and you can replicate such goals on a smidgen of the cost, that is my goal anyhow lol.
Keep on rocking as you roll in the creative dept.
If you can dream it you can build it. Excellent craftsmanship and design sir. Will be waiting anxiously for future videos and progress. Subscribed!
I am wanting to form a replacement wind shield for my motorcycle , out of .250 plexiglass.I need to heat it to 360 degrees and let it lay down on a form I'm going to make from the old wind shield that they don't make any more . You are the only person I have found that seams to know what they are talking about so my question is, what can I cover my formwith that will take the heat and not mess up the clarity of the finished windshield . I worked for a man years ago and helped him build and oven to blow form a window for a medical helicopter but I did not remember the temperature or what we put over the forms.Can you help me please.
you could possibly go into business blowing bubbles for custom cars. He he I did the same thing with camp stoves and a large OSB box and made a bubble for my 3 wheeled motorcycle.
+James Armstrong Ha ha. I've had 2 Vanagons in the past and currently have a 1991 mercedes 300D 2.5 exactly like the one on the vid. I also had a neighbor with a Volvo 850 Wagon the same color as the one in the vid. I was thinking this garage looks very familiar.
Cool Cars and even cooler electric car concept!
I'd love an update!!!
Nice man, Great vid.
Superb information. Many thanks for sharing and good luck with the full size model. Looking forawrd to seeing the results.
Great job Gary! ...but three videos in seven years makes me think your dreams never came to fruition. How's it going dude? Gotta give kudos to the dreamers that do...
If you opened a bakery instead I'm going to be seriously disappointed.
badass design.
I could be wrong but is it seems like the cart is coming before the horse, what about the drive system, suspension and interior? Those are all key elements that generally drive exterior packaging.
Thank You so much. I have many questions that what you have showed, may be or in part is what I have been searching for. I will gladly pay for your help.. I will soon email you. Thanks again.
Oh my god, you just made my day. I Have been looking at the best way to form back glass for my p.u. I used to see these types of windows alot back in the early to mid 80's but have not found any info as of late. thanks for the great video.
a while back when i was working for a job shop we built a oven that was 4'x8'x8' to heat up acrylic 1/2" acrylic sheets. we used one industrial covection oven as the heat source.
Was the room necessary? This seems similar to vacuum forming. Couldn't you use some heating elements above the plastic, and once it sags add air? Is there some piece of knowledge I am missing?
Hey Gary, came to think of this project and now see my own comment, seven years ago! Haha time flies, im so exited to see what happened =)
Did you dry the Lexan first? Were you able to form the big sheet?
lovely design and technique, how much it would be the thick of the final product?
Dude that’s crazy. And beautiful. Thumbs up.
Nice! 1. Do you make larger. 2. do you sell? 3. Whats the price?
You have done that in a great way! fantastic done. We will do business in the near future. yes
You should not have recorded the sound from INSIDE one of the bubbles! ;-D
gary you just gave me the anser iv,e been looking i want to form a giant p-51 to build a rc plane
cool video....
So much value in such a short time thanks a lot
Thank you for being so willing to help others. You are a blessing.
Nice.
how many air tube you used to blow the polycarbonate sheet?
gary lavarack how much would you sell one of these for
My right ear has now cheated on my due to neglect. -_-
Thanks for the vid!
2:46-2:50... the hub in the background tho
hello, what about a canoe shape ? is it possible?
You are pretty smart and that's badass but why use fiberglass insulation when polyurethane is like 80% more efficient. I bet your shop was warm during 4 ovens operation. Polyurethane doesn't burn at the temps ur using those 2x4s would be the weakest link. Experiment with the poly you'll love it
Polyurethane has a max temp rating of 250 f. not safe at temp needed to form poly.
It is that really 350 Degrees? I have tried to do the same and policarbonate always bubble like and alka-seltzer!! very disturbing quality . that make me quit using poly-carbonate! Never the less this was a very nice video, I meant it. thank you very much.
+Migueldeservantes You have to dry polycarbonate before putting high heat to it. We usually dry at 140 deg for 4-5 hours. After that you can heat it until it sags to the floor and it won't bubble.
+Joe Fox WOW !!! Your answer mean the world to me thank your so very much for answering, every one in the sign industry was telling me that it have to be done under a high pressure to avoid the bubbles. It is there any tell tell sign that it is ready for high heat??
+Migueldeservantes
People in the sign industry want to do the work themselves.
What causes the bubbles is moisture in the plastic. Most plastics are hydroscopic. When you heat the plastic without drying it the moisture expands and turns to steam making bubbles. Slowly heating it at a low temp for several hours cooks the moisture out without bubbling.
We use quartz heating tubes on our thermoformers and if were running sheets that haven't been dried we will heat the sheet very slowly for about 45 minutes then put medium heat to it for 20 minutes then finally bring it up to forming temp in the last 5 minutes for about a 1 hour cycle.
If the sheets have been dried we can heat a 1/4" sheet in about 6 minutes under high heat.
You know that one think about most polymers as as very solid material that can eve use as a moisture barrier!! but I guess that once "One have been working for long enough with this type of plastics.. one start to learn about it.
Thank you again and again!
thanks for the clip.......is the polycarbonate sheet need to preheat before the operation?i formed like this but make some buble inthe part after blowing....
you should pre heat the PC Sheet
Hi Gary, Thank you for the excellent video! We are a sculpture studio that is experimenting with thermo forming. We have been using acrylic, as we understand it is more UV resistant, and will be likely to yellow over time. The drawback of using acrylic, is that it becomes very brittle after forming, and is difficult to trim without breaking. My question is if we use poly-carbonate which is less brittle, can we expect yellowing over time, or is this a UV stable solution? Thank you again.
Seek out a UV-stabilized PC, the cheaper ones are not.
how did the full sized one come out?
The upside down forming was brilliant ,working with gravity.
Gravity doesn't suck...👍
This looks amazing.
Great build though
unbelievable , keep going
Very impressive project
any update on this?
Does the depth of the box built for blow forming have an effect on the outcome, or would it not matter if there was only a 1" void underneath the poly sheet, as long as pressure was built slowly and evenly?
+Kevin Ford it shouldn't matter at all, unless maybe the air flow into the box is such that it blows onto the hot plastic, causing deformation and local temp changes. Some sort of baffle / diffuser setup should prevent that.
lower box would be susceptible to warping as rigidity is reduced. If only 3lbs is applied it could be made from thinner steel instead of the heavy gauge beams shown here.
Just amazing
GREAT VIDEO
that was awesome
Great job!
Nicely done
Awesome!
Wow
You need to check the US patent office to be sure you are not violating existing patents.
Jerry Roane
We hold these truths to be sacred & undeniable; that all men are created equal & independent, that from that equal creation they derive rights inherent & inalienable, among which are the preservation of life, & liberty, & the pursuit of happiness; ...