Fabricating Solid Windscreen Sunvisor for 80 series

This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.

yuyoac

yuyoac

Joined
May 17, 2024
Threads
6
Messages
35
Location
mty mx
I've been looking for a windscreen sunvisor for a while, the only vendor that I've found online is located in AU and have a 40 week wait time, plus I'm located in NA.

So I'm thinking on fabricating my own, I found that they are made with solid steel, I'm thinking about substituting it for aluminum cheaper and lighter. Unless anyone knows where I might find one.

I was wondering if someone may have a diagram or a schematic of some sort, in which i could base the work on, I appreciate any help. Many Thanks!

(I attached a foto of the visor)

IMG_0966.webp


IMG_0964.webp


IMG_0965.webp
 
I’m in if you can find someone to make it. I’ve been wanting to do the same thing but no one I’ve spoken to is interested. From what I’ve gathered the demand isn’t big enough to justify the cost of taking it to market. I hoped one of the roof rack and accessory builders would bring one out. If one could be integrated into a rack system that would be cool.
 
I'm located in MTY MX, I've got some friends with a machining shop he also owns a LC, I'm just trying to find the radius of the angles, and general shape, so the fabrication can be more precise. I down to ship some out once Im able to make them.
 
All you need is some CAD design work....... "Cardboard Aided Design" easiest way to start and someone with sheetmetal experience, English wheel, Bead roller. Could be fun.
 
The easiest way to produce multiples is using modern techniques. I've got 25+ years as a body tech and doing metal/composite fabrication as a hobby on the side, and the English wheel is not the way to go. It's super slow, requires a skilled hand, and consistency is difficult to achieve. if youre making one, it could be done, but even 2 or 3 would be a pain.

If you want lightweight, mass production, perfect and consistent fit, you need to look at stamping steel or aluminum however, its crazy expensive to make a die and start producing. Or perhaps injection moulding from plastic ( but more expensive die manufacturing required), but you could have this done in Asia if you want to mass produce and sell them.

Other, smaller-scale and cheaper manufacturing methods are using composites like carbon fiber, fiberglass, etc., with molds. Vacuum forming could be done on a small-ish scale using polycarbonates or even ABS plastic, which would be very fast to make and light. Getting a single layer of plastic thin enough would be challenging, though. But how cool would a transparent smoked/tinted visor be?


I would do the following:

1) 3D scan upper windshield and pillars
2) Model the visor using CAD of your choice
3) 3D print a prototype
4) Make a mould of the successful prototype and produce small quantities in NA from carbonfiber. It looks cool raw. It's light and extremely stiff. It's also paintable and could be used with Nomex honeycomb in a sandwich format for extreme stiffness and weight savings.

Does anyone know what the Australian ones cost?
 
Loomin said:
The easiest way to produce multiples is using modern techniques. I've got 25+ years as a body tech and doing metal/composite fabrication as a hobby on the side, and the English wheel is not the way to go. It's super slow, requires a skilled hand, and consistency is difficult to achieve. if youre making one, it could be done, but even 2 or 3 would be a pain.

If you want lightweight, mass production, perfect and consistent fit, you need to look at stamping steel or aluminum however, its crazy expensive to make a die and start producing. Or perhaps injection moulding from plastic ( but more expensive die manufacturing required), but you could have this done in Asia if you want to mass produce and sell them.

Other, smaller-scale and cheaper manufacturing methods are using composites like carbon fiber, fiberglass, etc., with molds. Vacuum forming could be done on a small-ish scale using polycarbonates or even ABS plastic, which would be very fast to make and light. Getting a single layer of plastic thin enough would be challenging, though. But how cool would a transparent smoked/tinted visor be?


I would do the following:

1) 3D scan upper windshield and pillars
2) Model the visor using CAD of your choice
3) 3D print a prototype
4) Make a mould of the successful prototype and produce small quantities in NA from carbonfiber. It looks cool raw. It's light and extremely stiff. It's also paintable and could be used with Nomex honeycomb in a sandwich format for extreme stiffness and weight savings.

Does anyone know what the Australian ones cost?
Click to expand...
Solid is $334
Mesh is $264
Shipping $267
 
You must log in or register to reply here.

Share this page

Back
Top Bottom