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Laminating thin styrene instead of molding


joemac

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I wound up with a bunch of very thin, almost transparent, styrene that I'd saved, but didn't know what I would use it for.

Well, in the midst of building/modifying a Mack CF pumper project, I decided to start over. I bought another kit and began the modifications.

All the while working on it, I wondered about what to do with the first one.

It finally dawned on me that I could further modify it into a Mack C model, possibly my favorite truck.

This would mean that I would have to scratch-build the cab.

I made a simple mold/form, by gluing three disposable lighters together, side by side, and filling the gaps with putty. I then sanded it flat on the side that I'd filled. This gave me something to form the laminated styrene to.

I found that certain yogurt containers are also made of styrene; polystyrene, to be exact.

Look for the recycle triangle with the number 6 and the letters P S (poly styrene).

Cassette tape and CD cases are also styrene, but they're thicker, flat and rigid. I use them for flat body panels, doors, etc.

I started with a rectangular piece from the yogurt container and glued a sheet of the thin styrene to it and formed them to the lighter 'mold', using rubber bands to hold it overnight.

After that, it was just a matter of adding layers of the thin, red styrene and re-forming it onto the lighters.

When the thickness was getting close to what I wanted, I set some folded cardboard between the styrene and the mold, creating a slight arch, which was needed to achieve the appropriate shape for both the roof and the nose panel for the cab.

Both pieces are coming along quite nicely, actually better than I'd expected. When they're closer to being finished, I'll post some photos. That is, if the sun ever shines again.

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Very interesting technique, and I'm always interested in re-purposing other usually waste materials for modeling. Thanks for the reminder about the styrene yogurt containers too. I'd forgotten the nice molded curves some of them have. I've been using the polypropylene ones for mixing paints and epoxy for years. Looking forward to seeing some photos of your work here.

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OK, the first shot is of a few pieces that have been laminated to form the basic shape of the roof. A new piece is clipped onto the front, forming the beginning of what will be the 'brow' above the windshield.

Next to it sits the 'mold' made from the three lighters. It's not really bent. I don't know why it looks that way in the photo.

The second shot is of the two pieces that are nearly finished.

They're still a bit rough, but I think one more layer will do the trick.

The nice thing is, you can always add another layer if you screw up and remove too much material.

Once the glue has cured, it sands and files like a solid piece of styrene.

It's easy to manipulate small pieces into the piece, as the glue softens the smaller pieces, allowing easy integration and shaping.

Oh yeah, another source of smaller, but thicker pieces of styrene is the little 'clips' that are commonly attached to bread bags.

I'm always checking the recycle triangle on containers these days.

The wife gave me a large, clear container that something came in, as well as a black, rather rigid tray, both made of styrene.

On a similar note, the dollar store has five-packs of CD cases for... you guessed it... a dollar!

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post-7466-0-66908000-1392579949_thumb.jp

Edited by joemac
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