Smooth Wheel Covers Well kinda convex

[Verdann]

I think I'll put that in it's own thread as well.

[Craig]

Mine didn't turn out quite as nice...the resin wasn't mixed quite enough, so I ended up with a few uncured/lumpy spots. I'm going to clean up the mess I made and try again this weekend. I'm going to try a slightly different approach, and will post pictures of them as they progress.

[Craig]

[IMG][/IMG]

[IMG][/IMG]

Gave it another try yesterday; I peeled the first attempt off and took a different approach. This time I made a plywood frame to stretch the material over, stapled the T-shirt cloth on, then set it on a sheet of plastic so I could spread the resin mix on the cloth before setting it over the Saturn wheel cover. This worked really well! The material stayed tight with the weight of the plywood frame pulling on it. The first picture shows the OEM wheel cover with some tape around the valve stem so I could get a measurement of where it will protrude through the cloth. The second one shows a block of wood with four roofing nails pushing the material down into the lug nut wells; I'll cut these out so I can bolt the cover up to the wheel just like OEM. Will post more pictures later as I progress...

[Craig]

[IMG][/IMG]

I have two of them almost finished, with the third curing right now. I just had to take a quick picture to show what they look like in their semi-finished state. I discovered that the long valve stem will just fit under them if I leave the cap off, so I'll put a piece of tape over the end for now. I'll need new tires for it in the next few months, and will specify shorter valve stems.

[JRP3]

Had an idea that relates to another thread I just started about using window heat shrink plastic to mock up aero body mods. You could use the same thing to make a smooth wheel cover to test any gains, plus it would be clear so you could see your rims. Might not hold up well over time though, but it should be cheap and easy. You could even use it as a mold to make a fiberglass version, unless the polyester resin dissolves it You'd have to do some testing.

[Craig]

All four are done! Next step is to take a Dremel to the lug wells to sand the extra material back and blend it in with a bit of resin before I prime and paint them. I'll upload more pictures as they progress.

[Vekke]

https://www.facebook.com/home.php#!/...type=1&theater
Here is my todays achievements. They are about 50mm convex and manufactured from 3mm ABS. They needed to be more but that was too much without any tool to make. These have been made with my custom made CNC pizza pan cutter. Convex shape is manufactured under gas "grill" heat.

https://skydrive.live.com/?sc=photos...!305&sc=photos

You need only that thing where the flames come. 3 wheels etc for support for 14" wheel which is not on rim. Put the ABS to the center of the flame and start heating. 10-20mm convex shape you are able to get without any pressing. Gravity will do that much. If you need more you need some convex shape which you need to press down when the ABS is just starting to get on fire. If the ABS is too cold it wont go much. And after you have pressed it down once it starts to burn more easily. Today I was able to make 50mm offset convex shape with only pressing. If you need even more you and I need to have mold and that vacuum forming table.

[JRP3]

Really nice work.

[Geo Metropolis]

wow Vekke, those are really great. Mine are ABS but I just cut simple circles. Those look way more legit. Did you screw into the rim or are those attached to a hubcap?

[Vekke]

Those are screwed directly to rims which are replacement tire rims so there where no holes cooling holes in them like there usually is. So if you want to get 3.5-4" wide steel rims search for scrapyards etc. Center holes can be milled to your needs .