Headlight Lens Casting and more...

[NOBLNG]

I posted these pics on my build thread, but I figure this is a better place for them, so they may be of help to others. The headlights on that particular model are chrome, and to me that is unacceptable! I have read elsewhere on this forum, bits and pieces about Bondic and Laser Bond products. I decided to try it for myself using Bondic. I just used silly putty for the mold. The larger ones were a pre-test and the smaller ones are the ones I need. The whole process took about 30 seconds and I think they came out pretty good. They are not perfectly clear, but close enough for my liking. One could certainly cast any small parts with this stuff. I hope this helps someone.

Greg.

Edited February 4, 2019 by NOBLNG
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[Ace-Garageguy]

This is definitely helpful. I have many more projects that need headlight lenses than I have lenses, and I need to make copies where I only have one of what I need.

How does this stuff sand after it's fully hardened?

Edited February 1, 2019 by Ace-Garageguy

[Deathgoblin]

I do the same thing.  You might pick up a container of Alumilite 2 part molding putty.  It mixes together like Green Stuff or Milliput, and it stays pliable for about 15 minutes.  Once it sets it's like a silicone mold.  I just stick them in a drawer when I'm done in case I need another set. 

[Casey]

I've seen this movie before...

 

Edited February 1, 2019 by Casey

[Ace-Garageguy]

^^^   I thought that looked familiar.  

[NOBLNG]

35 minutes ago, Casey said:

I've seen this movie before...

Yes, Steven and others should get the credit for this idea. Thank You Steven!! I am merely simplifying it with the silly putty. It will work great for any small parts. It sands nicely. It seems a little harder and more brittle than styrene, but I was able to file the finger slot out on this door handle. This casting is a bit rough, but I was poking at it with a toothpick to remove an air bubble.

Edited February 1, 2019 by NOBLNG
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[89AKurt]

1 hour ago, Deathgoblin said:

I do the same thing.  You might pick up a container of Alumilite 2 part molding putty. [...]  

Ditto that!  I just tried that out recently, I need to learn how to get it to mold all the way, but easy enough to clean up the part.

Did you use two part clear epoxy?  That what Bondic is?

[stitchdup]

1 hour ago, 89AKurt said:

  That what Bondic is?

 

Bondic is the uv activated glue, if you do a search there is a thread here somewhere that explains it better than i can

[Ace-Garageguy]

1 hour ago, 89AKurt said:

 That what Bondic is?

 

[Casey]

2 hours ago, NOBLNG said:

This casting is a bit rough, but I was poking at it with a toothpick to remove an air bubble.

That seems to be one of the drawback to using this medium-- it has a high viscosity. Granted, I have only tried casting clear items with Alumulite's Clear Cast, but even that product was noticeably more viscous than common casting resins, making evacuation of air even more challenging. Even when the finished product was free of flaws, it yellowed after 16 month or so, while not even being exposed to any light. I hope these new products stand the test of time.

[Can-Con]

I used this stuff to make headlight lenses over 4 years ago and they're still clear, no yellowing. 

[ChrisBcritter]

Bondic has one quirk: it will pull away from the mold as it hardens unless you use thin layers. Alumilite also makes a UV-cured clear resin; it's a bit more viscous than Bondic but works out way cheaper.

[Deathgoblin]

I've used both.  Bondic tends to be clearer than regular "clear" 2 part epoxy which tends to have a little bit of a yellow cast.  The clear casting epoxy Steve listed above is clear as water and works really well, but the last container I had of it solidified before I could do much with it.   You might look into getting a UV nail lamp.  Then you could just put the mold in and let it go while you do other stuff. 

[StevenGuthmiller]

On 2/1/2019 at 10:45 AM, NOBLNG said:

Yes, Steven and others should get the credit for this idea. Thank You Steven!! I am merely simplifying it with the silly putty. It will work great for any small parts. It sands nicely. It seems a little harder and more brittle than styrene, but I was able to file the finger slot out on this door handle. This casting is a bit rough, but I was poking at it with a toothpick to remove an air bubble.

I take no credit for this technique.

I didn’t invent it.

I picked it up somewhere, but I have no idea from whom.

I like the silly putty idea.

Saves some time and your finished product looks great.

The nice thing about using mold putty versus something like silly putty is that you can save those molds and use them over and over again.

 

Steve

[NOBLNG]

1 hour ago, StevenGuthmiller said:

The nice thing about using mold putty versus something like silly putty is that you can save those molds and use them over and over again.

 

Steve

If you can remember where they are... I can't find my tweezers half the time. LOL.

Seriously, this bondic stuff is good for lots of little things. I just made a shifter lever for a Corvette with a little dab on a straight pin. I hate the little plastic kit parts.

Edited February 4, 2019 by NOBLNG

[StevenGuthmiller]

I keep all of my molds that I have made over the years in a plastic sandwich bag on a shelf in my shop.

I have molds for everything from various headlight lenses and buckets, to window cranks and mirrors.

You can do all sorts of small cast parts with Laser Bond or Bondic.

 

 

Steve