Thread: making a lip
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Old 06-23-2004, 05:32 PM   #11
satrya
Scooby Specialist
 
Member#: 5887
Join Date: Apr 2001
Chapter/Region: BAIC
Location: Fremont, CA USA
Vehicle:
2002 GDAA (bugeye)
797 (blaze yellow)

Default 3D contouring of layers of styrofoam

Quote:
so essentially if you were going to look at the styrofoam cutout, it would look like youre looking at the front of the bumper?
Precisely.
Quote:
that would take some pretty good carving skills, is there a better way to do this other than just eyeing it up?
Imho, I thought this is much easier than the multiple plywood / board method, at least when it comes to making a 3D contoured part.

As a visual aid to what I meant, here is a mid-process picture of a DIY wing riser I posted nearly a year ago here ( http://forums.nasioc.com/forums/show...hreadid=388312 ). I used acrylic instead of styrofoam but that is besides the issue.

On the left is a contoured part, compared with the layers of acrylic before contouring.

This is what I mean:

(1) Using styrofoam sheets & blocks of known length, width, and thickness, one can lay out a symmetric arrangement of these foam pieces, temporarily glued / affixed to the front bumper cover's bottom side.

(2) Do this layer by layer (i.e. arrange pieces of the same height for example), taking care to maintain mirror image between blocks placed on the right hand side and left hand side.

(3) Stack the layers in a similar concept as the wing riser photo above.

(4) Eye & draw a contour shape for each layer, perhaps just on one side.

(5) Remove all the foam pieces (taking care to number them so you know which one belongs to where).

(6) Copy the contour lines on the mirror image blocks.

(7) Put them back together, assembled as an integral piece (like the riser on the right).

(8) Start following the contour edges and make sure the "steps" dissapear, leaving smooth 3D contours in place.
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