Defender rebuild project

[Bods]

Nice work on that grill, be interesting to see how it goes on perforated type

I didn't expect the Speaker Grill to be plastic, having made some molds and had as some vacuum forming done locally advice was no pointed corners so he trimmed edge off one part of my mold, So I'd say it was rounded off to avoid issues like sharp corners, you could get some perforated plastic sheet and have them vacuum or thermoformed but Metal would be better and should have been used in first place really

Vacuum forming generally avoids sharp, 90-degree corners due to the risk of webbing (thinning or folding) and uneven material distribution. Instead, rounded corners (radii) or chamfers are preferred to help distribute stress more uniformly and improve the part's strength. Draft angles on the mold are also crucial for easy removal of the vacuum-formed part.

 

[Phils Arcade]

Nice work on that grill, be interesting to see how it goes on perforated type

I didn't expect the Speaker Grill to be plastic, having made some molds and had as some vacuum forming done locally advice was no pointed corners so he trimmed edge off one part of my mold, So I'd say it was rounded off to avoid issues like sharp corners, you could get some perforated plastic sheet and have them vacuum or thermoformed but Metal would be better and should have been used in first place really

Vacuum forming generally avoids sharp, 90-degree corners due to the risk of webbing (thinning or folding) and uneven material distribution. Instead, rounded corners (radii) or chamfers are preferred to help distribute stress more uniformly and improve the part's strength. Draft angles on the mold are also crucial for easy removal of the vacuum-formed part.

Been wondering that myself. I've got 2 types of perforated mild steel coming with slightly different sized holes and pitch sizes. Will see what it's like. Learned a lot from this first test piece, second one should be better.

 

[PAC-MAN]

Great stuff so far, well done, it's a nice project and I've been hoping to find something like this for some inspiration.

As for the woodworm... I have a Defender with the same problem, I sprayed it with some off the shelf ' commercial ' boring insect killer. I sprayed the cab four times to make sure I got the little gits using a weed killing knap sack sprayer and prepared the cab completely ready for primer. Anyhow, I didn't spray it, I left it over the winter to sort out in the spring. When I got to the cab to spray it, there were some new holes, only three or four but it was obvious what had caused the holes so I got hold of Wiltshire Pest Control and got the guys out and paid to have it done professionally. While they were there they sprayed the other cabs in the Garage and also all Timber that I had stored in there including the work bench. It wasn't expensive and worth while having it done properly. I would not waste time using off the shelf stuff again.

Anyhow, great work so far, keep em' coming and good luck with it. Awesome!

 

[Phils Arcade]

Great stuff so far, well done, it's nice project and I've been hoping to find something like this for some inspiration.

As for the woodworm... I have a Defender with the same problem, I sprayed it with some off the shelf ' commercial ' boring insect killer. I sprayed the cab four times to make sure I got the little gits using a weed killing knap sack sprayer and prepared the cab completely ready for primer. Anyhow, I didn't spray it, I left it over the winter to sort out in the spring. When I got to the cab to spray it, there were some new holes, only three or four but it was obvious what had caused the holes so I got hold of Wiltshire Pest Control and got the guys out and paid to have it done professionally. While they were there they sprayed the other cabs the Garage and also all Timber that I had stored in there including the work bench. I wasn't expensive and worth while having it done properly. I would not waste time using off the shelf stuff again.

Anyhow, great work so far, keep em' coming and good luck with it. Awesome!

The problem is that a lot of it has been eaten away so much, that it's crumbling away. I might be able to save a couple of parts, but will see.

 

[Phils Arcade]

Well the speaker grill samples arrived. This was supposed to be 0.5mm and 0.7mm perforated steel sheet samples at 300 x 300 mm per panel.
Thought the package was a tad heavy, then opened it and the sheets felt a little bit thick. Measured, and both were 1.5mm. Phoned the company to explain that they sent the wrong ones, and their reply was, "That is all we have in stock."

So why advertise the thinner material, take the order and confirm it. Should have at least come back to say they didn't have what I'd ordered in stock, and if I wanted an alternative. This is way too thick and heavy for the speaker grill, and would need a heavier press to form it. Back to searching again, ugh!

 

[Bods]

No wonder this country is such a state, what absolute morons, it's so annoying when you have to wait for things for a week to get wrong items

Are they Aldi workzone special calipers, looks same as mine but batteries leaked so I've got Lidl Parkside specials now lol

 

[Phils Arcade]

No wonder this country is such a state, what absolute morons, it's so annoying when you have to wait for things for a week to get wrong items

Are they Aldi workzone special calipers, looks same as mine but batteries leaked so I've got Lidl Parkside specials now lol

Yeah, definitely annoying.

These were Magnusson callipers from Screwfix. Think they were just under £20. Had them fore a while now.

 

[Bods]

Ah right, same Chinese product different name, Identical to my Aldi one with the little button batteries, think they were £9.99 and Lidl ones around same £9.99 or £12.99 which takes 2032 battery

This might help, I was thinking if I have any old bits from ghetto blasters but not sure if I have anything I don't need but thought of these Sharp grills that are done how you need to do them, give you an idea of how it will form and thickness

Seems these are about 0.7mm which is quite thin and dents easy as I'm always having to remove these to straighten and repaint which is pain being blue as they need a satin finish, so I don't think I'd go any thinner than that and say that's about the thickness you would be able to do without too much trouble

 

[Bods]

https://www.fhbrundle.co.uk/product...OADdpHolYgQOY0i38vZcAaIQ147jgjk9RK2UD8I7QF6lQ

Is that 2.5m x 1.25m size, as that seems quite decent price compared to others
must be weighing 11.15kg depending on hole spacing etc

 

[Kewydee]

Wow, I wish I had skills like that.
You'll end up with something lovely after all that work.

 

[Funhouse71]

I've used the Mesh Company when trying to make my Defender cocktail speaker grills they have loads of perforated mesh to choose from, think the 2 options below might be ok for what you want

https://themeshcompany.com/?s=round...ct","results_order":"desc"}&post_type=product

https://themeshcompany.com/shop/rod...ted-air-brick-covers-2-5mm-holes-0-6mm-thick/

 

[Phils Arcade]

I've used the Mesh Company when trying to make my Defender cocktail speaker grills they have loads of perforated mesh to choose from, think the 2 options below might be ok for what you want

https://themeshcompany.com/?s=round perforated mesh 0.7mm&jet_ajax_search_settings={"search_source":"product","results_order":"desc"}&post_type=product

https://themeshcompany.com/shop/rod...ted-air-brick-covers-2-5mm-holes-0-6mm-thick/

This is who I went through originally, but they couldn't get hold of the thinner material so sent out the thick ones at 1.5mm instead, not ideal. Almost impossible to shape properly without a 250 tonne press.

Have found another company but their payment site has been down lately, as trying to get samples.

 

[Funhouse71]

This is who I went through originally, but they couldn't get hold of the thinner material so sent out the thick ones at 1.5mm instead, not ideal. Almost impossible to shape properly without a 250 tonne press.

Have found another company but their payment site has been down lately, as trying to get samples.

Ah, Sorry, didn't realise this was the company you had issues with, hopefully the other company will come up with the goods