Thursday, May 15, 2014

Champion 77 Thread Lube Pot Liner

I am getting much more comfortable and skilled at using the 77, I have two pair of sandals completed so far.
However, I am and most likely will continue to use it about once a month and after cleaning and restoring the thread lube pot I realized that I simply will not leave the lube in the pot for weeks or months at a time. The lube drys slowly, thickens up to a syrup, and leaves a film all over everything.

I have been sucking out the unused lube with an ear syringe then cleaning and drying the pot but I thought that a liner would be the correct answer. It turned out to be an easy one day project that came out the 1st try.

I have a DIY vacuum form set up which is the ideal process to make this part.

1st I needed a pattern and decided to make a cast of the inside of the pot.
Two problems:
  1. Casting directly into the pot would require a release
  2. The pattern needs to be undersized to leave room for the plastic thickness.
I used an old die makers method of lining the mold (pot) with wax sheet which I happened to have from my plastic model making days. Its called Parafilm "M". By its self it is too thin 0.005" but that was OK because I could layer it and using the heat gun was able to get a nice thick lining, I was shooting for 0.030"

Next I mixed up some Bondo poured it in.

It popped out without hardly any effort! (I was shocked and worried)

I had to sand and put a finish coat of Bondo on it and then took it strait to the vacuum table without any finish or release on it.

Used some clear plastic from some packaging I scavenged and it came out perfect the 1st try (when does that ever happen?)

Yes it is fine, and yes I am obsessive compulsive!