outside mirror project

[turner_green]

Being an engineering/design buff and being in a love affair with Porsche 911's I have taken up the task of creating the vintage teardrop shape outside mirror while maintaining the internal electronics and controls that were available with the Porsche 911SC. So far I have a few drawings and a 3D model that I have created, and as I go about completing this project I will keep everyone updated.

[turner_green]

my attempt at a 3D scale model

[poorsha]

Cool.
You need one of those 3D machines that builds things out of plastic (?)

[Eric Hahl]

Very cool. Can't wait to see the outcome.

[turner_green]

I am hoping that I can get it printed in 3D using one of those printers but if not I may have to use clay or some other material that i can create a much more presentable prototype by hand. The final product I intend to have milled out from a single piece of circular aluminum tube.

[dipso]

I thought the teardrop was always aftermarket. I had chrome/ stainless flags, and then the painted flags.
I never knew that the teardrop was original. Interesting.

[turner_green]

My initial idea was to have this made out of aluminum but there is the option of carbon fiber. I like the idea of carbon because of how light it is and how rigid it would be, and of course the cool factor of it all but I am unsure weather its worth trying out a carbon version over the initial aluminum designs. What do you guys think would be a good option?

[Eric Hahl]

My 2 cents...It's a retro looking mirror and might look better in aluminum. Also, I could be wrong and probably am but I thought I heard that carbon fiber breaks down with UV and would need painted for protection. Would a clear coat protect it?

[RWebb]

you could paint it with an aluminized paint like Wurth silver...

[vulcan300]

For prototyping you could have it printed in nylon by Shapeways.com.

[turner_green]

thanks for the help guys, I would need to paint it to protect it, but I do agree with you about aluminum would give it that retro look that I am going for.

[Norm Faustino]

A cheap way to do this is to stack urethane foam, which is resistant to resins and catalysts and shapes really well with simple cutting tools and sand paper. Then you can cover it with glass cloth and resin and you have a reasonably hard shell with which to make into your prototype. I used this process on my customized 79 mini clubby. to fill in the factory stamping for the front fascia. Pics below.

[airfix4]

I have a 3d Printer and could take a look at it if you want. What was the native model created in?

[jittsl]

I love the little clubby. May have to get me one of those. In my misspent Australian youth I owned a total of 14 different real minis culminating in a genuine Cooper "S". I loved those cars.

[turner_green]

Originally Posted by airfix4

I have a 3d Printer and could take a look at it if you want. What was the native model created in?

Currently the model is created in google sketch up but I am finalizing the dimensions so I could get it drawn up in solid works. That way I have more of an industry standard file to send to a printer like yourself or the manufacturer.

[airfix4]

When you finalized the dims you can export from sketchup as an .obj file, which I can manipulate for my printer...no pressure either way. I have several projects I'm working on so I can't promise turn around time right now.

[turner_green]

A quick update on the progress:

I luckily have a friend with a Makerbot and he was nice enough to do the 3D printing for me, so once that is in I will be posting the pictures. I have also just purchased a pair of 911SC stock outside mirrors so I can rip out the electronics and use them for the prototype with the 3D model.

Once that is completed I can continue to designing the stem and ultimately the final product.

[turner_green]

just a quick update. The 3D printing is done and I have received and started the teardown of the stock mirror and am in the process of mocking up the mounts of where the existing motors will go. Next step is to mock up the mounts and get them printed as well to have a full working prototype.

[turner_green]

I was successful in taking out the electronics from the stock 911SC mirror and with some modifications to the overall size I was able to fit the electronics into the prototype. The next step is to test the electronics and make sure they work and then I will begin to install the mounting arm.