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Hey Yunz all!!!
Heres another little project for those interested. Build a mini Vacuforming unit. Now the object of this idea was driven by the size of the styrene sheet that I can find/buy. Locally. I can only get sheets 21"x 8" and 1mm thick from my local hobby shop. Its kinda an odd size but its easy to get.
STEP 1...
First thing. I bought a small utility container 4.5"x 7". One that is segmented inside. These will give inner support to the box structure while under suction. I drilled 1/4" vent holes in the dividers to allow airflow or vacuum in this case. I then drilled a large hole in the lid for the vacuum connector. This is a 1/4 inner diameter threaded elbow connector you can find at the hardware store.
STEP 2...
Turning the box over. The bottom will become your vacuforming work surface. On the container bottom. I drawn a grid with a sharpy of lines spaced about 3/8" apart. Where the lines intecected I drilled a hole with the smallest drill bit I have (Dremil tools usually come with a 1/32") If the lines intersect at the base of the inner dividers, drill a little to the left or right. My brass connector was epoxied in place inside and outside of the lid. This will complete the Vacuformer work surface. Close and seal the box shut. Glue the lid shut and for added seal cover the edge with duct tape.
STEP 3...
This is more plumbing supplies from the hardware store. I believe this connector is for a sink/faucet connection. It is water tight. I added a 1" inner diameter PVC pipe connection. This will connect to my house hold vacuum cleaner hose. (I had to add a little duct tape to snug it up inside the vacuum hose)
Here's a close up of the PVC connector. Inside these threaded connections I used epoxy to make them air tight. (You could even use elmers as long as you let it dry.)
STEP 4...
Make your frames. They must fit your vacuformer. These 2 frames will hold the styrene sheet between them. I used yard sticks. (Wood doesnt conduct as much heat like metal.) They are held together by angle brackets (More hardware store stuff) I only used the metal brackets on one side of each frame. Remember the other side must be a flush/smooth surface to hold the styrene tight.
Here you see the frame in relation to the vacuformer work surface. The metal brackets are placed facing outwards as the image shows.
STEP 5...
The fun bit. Make your subject. Here I had taken a old mego torso. I cut it in half and glued craft foam to give an armour look. The button glued to the chest should give you an idea of who this armour is for!!!
STEP 6???
I kinda jumped ahead with this image. Here you see how the Styrene is held between the frames. I use 1" clips to keep the frame styrene sandwich tightly together. This frame styrene sandwich is placed in an OVEN. Not directly on the rack. The frame must be propped up away from the oven racks. I usually place the frame on a pot so the styrene is free to droop when heated. NEVER LEAVE YOUR PROJECT WHILE HEATING. When you see the styrene drooping/sagging inside the frame. It is ready for vacuforming. Activate the vacuum cleaner that you connected to your vacuformer. Using oven mitts,remove the frame/styrene sandwich from the oven and lower it onto the vacuformer. Try to get the frame arround the box Like the second image in STEP 4. The suction will pull the styrene tight arround what ever is lying on the vacuform work surface (My body armour). I let the styrene sit under vacuum a couple of minutes to allow it to cool. When its done. Turn off the vac. Remove the frame and pull out your subject. My body armour positive popped out of the styrene easily. The finished result is what you see in the finale photo. Now all I have to do is trim and paint and attach to my project. Hope it goes this easy for you too.
Heres another little project for those interested. Build a mini Vacuforming unit. Now the object of this idea was driven by the size of the styrene sheet that I can find/buy. Locally. I can only get sheets 21"x 8" and 1mm thick from my local hobby shop. Its kinda an odd size but its easy to get.
STEP 1...
First thing. I bought a small utility container 4.5"x 7". One that is segmented inside. These will give inner support to the box structure while under suction. I drilled 1/4" vent holes in the dividers to allow airflow or vacuum in this case. I then drilled a large hole in the lid for the vacuum connector. This is a 1/4 inner diameter threaded elbow connector you can find at the hardware store.
STEP 2...
Turning the box over. The bottom will become your vacuforming work surface. On the container bottom. I drawn a grid with a sharpy of lines spaced about 3/8" apart. Where the lines intecected I drilled a hole with the smallest drill bit I have (Dremil tools usually come with a 1/32") If the lines intersect at the base of the inner dividers, drill a little to the left or right. My brass connector was epoxied in place inside and outside of the lid. This will complete the Vacuformer work surface. Close and seal the box shut. Glue the lid shut and for added seal cover the edge with duct tape.
STEP 3...
This is more plumbing supplies from the hardware store. I believe this connector is for a sink/faucet connection. It is water tight. I added a 1" inner diameter PVC pipe connection. This will connect to my house hold vacuum cleaner hose. (I had to add a little duct tape to snug it up inside the vacuum hose)
Here's a close up of the PVC connector. Inside these threaded connections I used epoxy to make them air tight. (You could even use elmers as long as you let it dry.)
STEP 4...
Make your frames. They must fit your vacuformer. These 2 frames will hold the styrene sheet between them. I used yard sticks. (Wood doesnt conduct as much heat like metal.) They are held together by angle brackets (More hardware store stuff) I only used the metal brackets on one side of each frame. Remember the other side must be a flush/smooth surface to hold the styrene tight.
Here you see the frame in relation to the vacuformer work surface. The metal brackets are placed facing outwards as the image shows.
STEP 5...
The fun bit. Make your subject. Here I had taken a old mego torso. I cut it in half and glued craft foam to give an armour look. The button glued to the chest should give you an idea of who this armour is for!!!
STEP 6???
I kinda jumped ahead with this image. Here you see how the Styrene is held between the frames. I use 1" clips to keep the frame styrene sandwich tightly together. This frame styrene sandwich is placed in an OVEN. Not directly on the rack. The frame must be propped up away from the oven racks. I usually place the frame on a pot so the styrene is free to droop when heated. NEVER LEAVE YOUR PROJECT WHILE HEATING. When you see the styrene drooping/sagging inside the frame. It is ready for vacuforming. Activate the vacuum cleaner that you connected to your vacuformer. Using oven mitts,remove the frame/styrene sandwich from the oven and lower it onto the vacuformer. Try to get the frame arround the box Like the second image in STEP 4. The suction will pull the styrene tight arround what ever is lying on the vacuform work surface (My body armour). I let the styrene sit under vacuum a couple of minutes to allow it to cool. When its done. Turn off the vac. Remove the frame and pull out your subject. My body armour positive popped out of the styrene easily. The finished result is what you see in the finale photo. Now all I have to do is trim and paint and attach to my project. Hope it goes this easy for you too.
MY GODS ARE SMALL...... AND 
Thanks!
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