W [=0===0=] TR Run One Project Updates

[BoxGods]

I created a new thread to keep First Run Reservation Holders updated on our progress.

For anyone who is curious what the tooling, (also sometimes called a mold) used for roto-molding looks like:



The mold is manufactured from cast aluminum using a process called lost foam, and then is precision CNC machined to it's final shape.

The mounting frame on the bottom will be clamped or welded to to a structure on the roto-molding machine called a spider. The mold top is unclamped and removed, a specified amount of powdered plastic is poured into the mold, the top is clamped back on, then it is placed into an oven. It is then continuously rotated on all three planes as it is slowly heated. Once the heating and hold cycle are completed it is removed from the oven and given a specified amount of time to cool--all while still rotating. Once it has cooled the top is popped and the part is removed. The cycle is then repeated.

I will try to get some video of the mold in use if at all possible.

[BoxGods]

A few renders of how the mold tooling works for anyone interested in the "nuts and bolts" of tool making and the roto-molding process.





You can start to get an idea of why the tooling for projects like this is so expensive.

[BoxGods]

These are renders of the final, (hopefully) tank shape. The roto-molding factory still has to sign off before we go gold on the mold tooling but we are either there or very close I think.

I had to revise the handle shape slightly to facilitate part removal from the mold. Otherwise it is largely unchanged from the original design.





It's actually a pretty interesting looking shape =)

[BoxGods]

The mold tooling has progressed through foam core machining and aluminum casting. The newly cast "shells" are now ready for CNC machining and post processing. The tool should be done and a test part pulled from it in about 2 weeks. Still on schedule for a mid to late May ship date--as always that is pending unforeseen delays. Do not make firm plans based on that date as there are a LOT of variables.

[BoxGods]

A quick update for some of the non roto-molded tank parts. These are pre-production validation samples for the custom parts we are manufacturing to double and triple check everything fits together and performs as expected before the production run. This is different from prototyping as its purpose is to confirm the manufacturing processes.




Starting at the top and moving counter clock-wise, this is the CNC machined PVC hatch plate, vented fill port cap, molded in place brass GHT male threads, and the brass unified sprayer hose connection with barb. The gray hatch part is fresh from the CNC mill so it still hasn't had post processing to remove the machining marks--don't panic =)



This is the bottom side of the hatch plate with the hose barb showing. A tube runs from that barb to the submersible pump. You can see the coiled sprayer hose hanging down also. The unpopulated hole above the rectangular cutout is where the pump power wire will be potted in for a water tight pass-through



This is the vented fill port cap screwed onto the brass molded in garden hose threads. The layered brass portion you see is what is roto-molded into the water tank. The molten plastic flows into those layers and around the irregular shape which locks the brass fitting into place.

The little hole you see in the side of the cap, (there are actually three of them) are to allow air into the tank when your are using the sprayer. When screwed all the way down they seal water tight. I made the caps over-sized, (aka "chonky") for an easier grip, and bright ass yellow so they are easier to find after you have set them down somewhere in the frunk while filling the tank.



This is the same brass molded in GHT threads from the last picture with the vent cap removed and the clear fill hose attached, and the time I mentioned that you are likely to misplace the fill caps =)


As always, I'm happy to answer any questions you might have.

[phatman113]

Love the updates, it's not a process I'm particularly familiar with, so it's really fun to see all the work that goes into this. Thanks for keeping us informed!

[BoxGods]

Mar 29, 2023 15:19:26 GMT phatman113 said:

Love the updates, it's not a process I'm particularly familiar with, so it's really fun to see all the work that goes into this. Thanks for keeping us informed!

Happy to do it. I have been doing this for something like 30 years and I still find it endlessly fascinating--especially on projects like this =)

[jcreviston]

Really appreciate the attention to detail and willingness to share each step of the way. Was just thinking how happy I am to invest when I get to be privy to the process start to finish! Can't wait for it! 

[BoxGods]

Mar 30, 2023 5:14:27 GMT jcreviston said:

Really appreciate the attention to detail and willingness to share each step of the way. Was just thinking how happy I am to invest when I get to be privy to the process start to finish! Can't wait for it! 

Thanks Jacob =)

I am hoping the roto-molding factory will get some pictures or even video for us that I can share too.

[bksnacker]

Any experience with glow-in-the dark plastic parts? Is that an easy thing to do with these molded part? I find myself setting up in the dark a lot.

[BoxGods]

Apr 2, 2023 19:17:50 GMT bksnacker said:

Any experience with glow-in-the dark plastic parts? Is that an easy thing to do with these molded part? I find myself setting up in the dark a lot.

That's an interesting thought. I would need to see a whole lot of long term testing data on human toxicity before I felt comfortable using it in a water storage container though.

[phatman113]

Apr 2, 2023 19:17:50 GMT bksnacker said:

Any experience with glow-in-the dark plastic parts? Is that an easy thing to do with these molded part? I find myself setting up in the dark a lot.

I would think it wouldn't get a lot of light in the frunk to glow though, right?  Is the hood magnetic?  I haven't tried, but maybe just a magnetic lamp that you can stick on the hood  when you're working in there would work better?

[BoxGods]

Apr 4, 2023 22:09:12 GMT phatman113 said:

Apr 2, 2023 19:17:50 GMT bksnacker said:

Any experience with glow-in-the dark plastic parts? Is that an easy thing to do with these molded part? I find myself setting up in the dark a lot.

I would think it wouldn't get a lot of light in the frunk to glow though, right?  Is the hood magnetic?  I haven't tried, but maybe just a magnetic lamp that you can stick on the hood  when you're working in there would work better?

Doesn't the frunk already have a light? If not...there is the flash light in the door. Of course if you're stargazing you will want a red shifted light anyway.

[leonbmx]

I'll echo the other's sentiments, awesome to see "How it's made"! I'm an Aeronautical Engineer and we don't often use roto molded parts, at least not on my part of the airplane, so this is really cool to see!

[BoxGods]

Apr 11, 2023 13:34:12 GMT leonbmx said:

I'll echo the other's sentiments, awesome to see "How it's made"! I'm an Aeronautical Engineer and we don't often use roto molded parts, at least not on my part of the airplane, so this is really cool to see!

Yeah I think Boeing uses some roto-molded ventilation ducting and probably some non critical tankage--just guessing though. I can't think of any other places to use it that make sense off hand. IIRC they had issues with roto-molded parts early on--like the early 70's--and the process was put on the "no. don't even ask" list for engineers. As an AE I'm sure you know how arduous the politic of change are at companies like that.