[warrenpenalver]

Whoooaaaa Slow down peeps!!

This is at experiment and research stage

Ive got some cheap resins and moulding materials to play with for now and once ive done some experimenting and pre-productions i might try and make some proper ones.

[warrenpenalver]

Well ive made my first mould and it has come out pretty good!!!



shall see if i can make a resin cast later!!

[daz x]

lookin' good so far Warren.Hope you have success with the casting.

[shinigami]

Wow, looks good that mould, nice clean lines.

I really hope you can manage this, you'll have hundreds of people after them if you end up making badges fairly close to the original.

You'll end up wishing you didn't, lol

[warrenpenalver]

I shall try casting one this evening. Takes 24hours to fully harden.

Id need to make a better mould for "production" anyway as theres a couple of small imperfections on the edges. Probably use liquid silicone to do that mould. I suspect i will need the expensive resin to get the perfect optical clarity needed.

[RED IMPACT]

Well ive made my first mould and it has come out pretty good!!!



shall see if i can make a resin cast later!!

Im sure pretty much everyone with an FRP would buy at least 1 set and then a spare set if this turned out good. Once the FRP lot have been sorted, im sure quite a few of the zsoc lot would be interested in a few sets also!

Fingers crossed this has a happy Disney style ending!

[shinigami]

All sounds promising so far.

Just a thought, you mentioned graphic substrates with glues being obtained using makers of the domed badges with silver Ford lettering.

Would it be possible to obtain these to rejuvinate original badges? I'm considering it with ones I've just got from Ebay. I'm thinking of maybe sanding off the original graphic and sticking a new one on.

This post has been edited by shinigami: 22 September 2008 - 04:43 PM

[warrenpenalver]

Getting the substrate sticker is easy enough. If you are confident at removing the old sticker substrate cleanly then should work.

[shinigami]

Good point, It would need to be removed but also leave a perfect finish so that the new sticker will be seen without any defects I guess.

How easy is it to apply a new substrate sticker?

[warrenpenalver]

You can get the clear thin glues easy enough. Applying the sticker to the clear bit of plastic once youve got the glues etc is simply a case of steady hand and eye. You could probably measure up and put some allignment marks on sticker. Thats probably what i will do, have allignment marks put on the sticker backing to line up with the badge. Obviously these would be left on the backing paper as the badge is cut to shape on the backing in the factory. (well it can be if i specify it)

[warrenpenalver]

First prototype:


It is cloudy because i havent used a release agent as its like £15 a tin for the high quality stuff i want!!!!

Im quite pleased with the outcome!! The lines and shape is clear and only tiny amount of "flash" at back of the badge which comes off easily!! I shall polish it up and put a printed paper ford racing logo under it to check optical clarity!!

[warrenpenalver]

the only other change i will make is if i can get an old kackered ford racing badge from someone i will remove the glue and logo and make a new casting the EXACT plastic thickness as this prototype is about 1/2 mm too thick.

[Pnthrblkzs]

the only other change i will make is if i can get an old kackered ford racing badge from someone i will remove the glue and logo and make a new casting the EXACT plastic thickness as this prototype is about 1/2 mm too thick.

Looking good so far!

I can sent you a knackered badge if you like to guage the thickness. A corner of the Ford part of the badge has snapped and been glued back on though, if thats not a problem its yours.

PM me your address and i'll get it sent.

This post has been edited by Pnthrblkzs: 25 September 2008 - 07:18 AM

[warrenpenalver]

Rather than spending ages polishing the resin i cheated did it with nail varnish instead

But dont worry this is a prototype i done this just to get a look at the optical clarity of the resin.

This picture shows the resin badge laid ontop of a standard badge. Im pleased its come out clear!!! the white speckling is bits of dust when i nail varnished it!! There were only 2 tiny bubbles i could see in the plastic and i can remove these during manufacture by heating the resin up in a bowl of boiling water and also haridrying it when in the mold to remove pouring bubbles.

Im quite pleased with the results:


I just need to source a decent resin for the final products and a qoute for the lettering substrate and glues.

[daz x]

lookin really good for a first attempt.I reckon every frp owner on here will want a couple of sets if you do go into production with them.

[happy-kat]

looking very tidy work Warren

[warrenpenalver]

when i get to the stage of production i will probably make a few more moulds so i can batch cast as bigger quantitys are easier to mix in the right proportions. The cheapo resin im using now is 50/50 resin/hardener where as the expensive resins are like 3% hardener which is hard to measure when you only need 15ml mixed product to easily cast the badge!!!!

Also ineed to get the right colour match for the light tint of the original plastic. Might take a few practices to get the right amount.

[shinigami]

Seriously good effort there. It looks like finally someone has managed the impossible... which was quite obviously very possible with a bit of knowledge. I can't believe companies couldn't be bothered to try making any like this when people enquired.

What do you think the costing could end up being for each badge or set if this takes off?

[Dogsbody]

Looking really Good.
Add me to your list when you go into full scale production, Please Warren.

[warrenpenalver]

I can't believe companies couldn't be bothered to try making any like this when people enquired.

What do you think the costing could end up being for each badge or set if this takes off?

Companies wont bother because for the volume we want its not financially viable to do an injection plastic mould and the resin ones are time and man labour intensive. Plastic injection machines could easily knock out hundreds of units an hour where as resin has drying times.

The domed badges on ebay are dead cheap to produce in large quantities.

Cost break down so far is looking like this: (no garuntees!!)

approx £2 a logo substrate including the proper silver foil ford logo rather than printed silver which is grey on many cheap domed badges.
between £1-4 for resin, release sprays and moulding silicone (silicone moulds have a lifespan).
approx £1 each badge for glues
Packing and recorded delivery about £1.50 max.

So between about £5.50 and £8.50 a badge not including any labour.