For those unfamiliar with it, Bocce Ball is an outdoor game played with a set of heavy grapefruit-sized balls. We’ve never really thought of making our own set, but as you can see above, it can be done. These are six Bocce balls produced at home by [Horvitz444].
It seems the commercially available balls have a cement or clay core covered in a layer of high-impact epoxy. [Horvitz444] was able to recreate this starting with some vacuum forming. He built his own former out of peg board and a shop vac. The plastic stock he used was a light panel from the home store. After heating it up in the oven he formed a mold using what looks like two halves of Bocce balls. The mold halves were melted together using a soldering iron. After pouring in the secret concoction of cement ingredients and letting them harden, he removed the orbs from the molds and ground down the seams until smooth. They were covered in epoxy and painted. Most of these details were gleaned from his comments in the Reddit thread.
[James] builds all sorts of robots and superhero costume replicas at home, so he is always searching for a better way to get consistent results when using his vacuum table. A lot of people use their oven or exposed heating coils from electric frying pans to warm the plastic sheets, but [James] wasn’t really interested in going down that route. He cites that he would rather not heat plastic in the oven where he cooks his food, nor is he really keen on the idea of exposed heating elements.
Instead, he opted for a slightly pricier, though completely reasonable setup that produces consistent results every time. Most of the forming table was built using MDF sheeting, as you can see in the video below. His heating apparatus was the most expensive part of the rig, since it’s an off the shelf quartz-based room heater. He lays the heater on its back side, and directs the heat up through an MDF frame using aluminum foil as a reflector. The plastic sheeting mounted at the top heats evenly, and in no time, he has a perfectly vacuum formed prop that is ready to be painted.
Sure, it might cost a bit more than some other vacuum formers we’ve looked at before, but spending a bit more up front to get consistent results is well worth it if you ask us.
Continue reading “How to build a vacuum form table that gets it right every time”
[Harrison Krix] finished his Daft Punk Helmet replica and posted about it this week. We took a look at his work back in October but he’s come a long way to pull off a legendary build. Take three minutes after the break and see 17 months worth of work. So many skills were pulled together to make this happen; sculpting, mold making, painting, electronic design, mechanical design, and bad-ass-ery. Crammed in along with your noggin are a bag-full of LED boards but the Arduino that controls it all resides outside, in a project box tethered to the helmet. This is a masterpiece of socially-unwearable geek fashion.
Continue reading “Daft Punk Helmet replica finally completed”
Vacuum formers are still fairly rare in our community, so it was a surprise to see that in the 1960s Mattel marketed one as a toy. It used a hot plate to mold plastic sheets into various shapes. The design was updated by Toymax in the early ’90s to use a light bulb heating element to make car bodies, like some sort of manly Easy-Bake Oven. The home-built machines we’ve seen are a much larger scale. In 2005, we posted [Ralis Kahn]’s version that employed an electric grill as the heating element. [drcrash] has since built on those plans, hoping to develop an even cheaper device.