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DIY fiberglass reinforced E&F build
- Thread starter kaljukajakas
- Start date
kaljukajakas
Active member
It's pretty over the top DIY 
The process is called "plug assist vacuum forming". The polystyrene is clamped in the plywood frame (platen) and placed in an oven at 375 deg. F until the plastic sags several inches in the middle. Then the platen is placed on the female mould so it seals and the plug is used to stretch the plastic into the mould. Then the vacuum is applied (I used a vacuum cleaner) to suck the plastic flush against the walls.
It's pretty tricky to get right as it has to happen in about 10-15 seconds and everything needs to be lined up. It's difficult to perfectly position the plug assist on the sagging hot plastic in just a second or two and then immediately (with a rate of one foot per second) force it down straight into the mould while turning on the vacuum cleaner with your foot...
The process is called "plug assist vacuum forming". The polystyrene is clamped in the plywood frame (platen) and placed in an oven at 375 deg. F until the plastic sags several inches in the middle. Then the platen is placed on the female mould so it seals and the plug is used to stretch the plastic into the mould. Then the vacuum is applied (I used a vacuum cleaner) to suck the plastic flush against the walls.
It's pretty tricky to get right as it has to happen in about 10-15 seconds and everything needs to be lined up. It's difficult to perfectly position the plug assist on the sagging hot plastic in just a second or two and then immediately (with a rate of one foot per second) force it down straight into the mould while turning on the vacuum cleaner with your foot...
KING_JOHN_C
Member
interesting project.
