Making Rover R8 early grey bumper air vent inserts

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alviseven
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Making Rover R8 early grey bumper air vent inserts

#1 Post by alviseven » Sat Apr 23, 2016 12:04 am

My twins are missing the little plastic air baffle that fit inside the front bumpers at the lower air intake level. I have one OE part and think the idea of finding the missing ones are remote now. So have drawn a pattern up on CAD to run through a laser cutter to make a sample. Have good access to clear acrylic but this is clearly neither the right colour or the right material as it will shatter easily on impact - stone damage.
Anyone able to confirm the original material - I have some grey ABS on the way to me but think this is going to be too hard to laser but so am thinking to try some HIPS as its more reliable to cut without fumes and has reasonable impact resistance. They are identical in size despite the photo looking otherwise.
Rover inserts (Small).JPG
Rover inserts (Small).JPG (98.25 KiB) Viewed 1205 times
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Johnny 216GSi
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Re: Making Rover R8 early grey bumper air vent inserts

#2 Post by Johnny 216GSi » Sun Apr 24, 2016 2:34 am

http://info.craftechind.com/blog/bid/39 ... e-Industry

The selection of plastics for any application is quite specialised. They obviously all have a huge number of different properties. Chemical companies such as ICI advise on plastic selection for stringent requirements such as temperature range, minimal shrinkage, discolouration and onset of brittleness over time, but the above should give you some good ideas. It's a case of use-what-they-use to bypass the learning curve.

Typing "polypropylene sheet" into Ebay reveals a number of cheap sources :wink3 Not sure about its emissions whilst being laser cut though.

HDPE (High density polyethylene) is meant to be one of the safest/greenest plastics. But maybe too soft for the application?

^^^^ Nice work by the way. If we could 3D print our way to a full selection of spares, that's us all sorted!
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alviseven
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Re: Making Rover R8 early grey bumper air vent inserts

#3 Post by alviseven » Thu Apr 28, 2016 7:32 pm

Some success as have fitted the first production samples - or more probably the pre production type units to my car. They look the part. I have added a pair of small holes to allow me to add a cable tie.
Next up is to look at the inner baffles as mine are missing from one car and age decayed on the other - so it is back to the drawing board.
Attachments
New tie insert (Medium).JPG
New tie insert (Medium).JPG (38.44 KiB) Viewed 1143 times
Original with production unit lower (Medium).JPG
Original with production unit lower (Medium).JPG (69.66 KiB) Viewed 1143 times
Fitted (Medium).JPG
Fitted (Medium).JPG (56.42 KiB) Viewed 1143 times
Twin G reg Red 216GSi Rovers

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GTiJohn
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Re: Making Rover R8 early grey bumper air vent inserts

#4 Post by GTiJohn » Thu Apr 28, 2016 8:08 pm

They look great.

They we're put in to reduce aero drag and were surprisingly effective at reducing the wind tunnel figures. I wonder if you'll see any real-world effects...
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Re: Making Rover R8 early grey bumper air vent inserts

#5 Post by montegoman » Thu Apr 28, 2016 8:33 pm

That looks dealt good. I will be putting an order in for No.1 as the n/s one is missing.
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alviseven
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Re: Making Rover R8 early grey bumper air vent inserts

#6 Post by alviseven » Tue May 24, 2016 9:29 pm

Now started on the inner rad pillar mounted units which are again both missing on one car and damaged on the other. Using the damaged patterns I have both left and right drawn out. Even replicated the L and R on the inner edges!
Made a wooden mould up to put the heated flange into to bend the item to shape. Prototype left hand out today and fits nicely and barely see the differences between the original and mine.
Attachments
IMG_8584.JPG
Prototype RH inner infil
IMG_8584.JPG (53.42 KiB) Viewed 1042 times
jigged up.jpg
Wooden former to mould to shape
jigged up.jpg (87.29 KiB) Viewed 1042 times
Twin G reg Red 216GSi Rovers

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GTiJohn
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Re: Making Rover R8 early grey bumper air vent inserts

#7 Post by GTiJohn » Wed May 25, 2016 6:11 am

Another overlooked part of an R8 - good for cooling and drag.

Love the L & R!
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