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GB: Aluminum Map Pocket Lid (driver door) - SakeBomb Garage

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Old 03-10-11, 07:16 PM
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Old 03-10-11, 07:49 PM
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Old 03-10-11, 09:12 PM
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Old 03-12-11, 04:36 AM
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I just received the quote for the lid cover today, and it is not cheap by any means . We would love to make the cover but will need much higher numbers of people on board to break even (which is our only goal for this project). There are other (cheaper) casting methods available, but for dimensional and aesthetic accuracy we won't be using them. Dan and I have thoroughly discussed this, and feel that the modest increase in cost is well worth it for an identical part. For 50-75 dollars I'd rather not have an eye sore that doesn't match the plastic pieces that it sits in between, in my car... that's just me. If you want to nickel and dime your FD, I assure you there are other options/companies out there, though if you really want a cheap fix try some JB Weld

The Process:
For those who don't know, the casting method that we will be using is the "rubber mold casting" process. Unlike sand casting (which is done by pressing a hand-carved wood form into sand), this process uses a special 2 part rubber mold which is made from taking a direct impression from the original part. This ensures not only dimensional accuracy and identical shape, but yields an extremely high "resolution" copy of the part (unlike sand). This allows even the surface texture of the new part to be retained from the original piece. After the 2 part positive mold has been created, a super-fine ceramic slurry is poured into the mold creating a negative. After drying, the ceramic negative is removed, and put in an extremely high temperature oven to fuse the ceramic shell into a solid structure so that it may accept the molten aluminum. A ceramic "filter" is then inserted into the shell and molten aluminum poured in. After cooling the ceramic shell is cracked off to reveal an identical copy of the part. The air gates are then removed and the part is ready to be moved to the next process which is finishing machine work, tapping, drilling etc. As you can see the process to create each part is quite involved, however the result is a dimensionally and aesthetically identical part. We use this same process for our passenger door handles.

https://www.rx7club.com/showpost.php...41&postcount=1


The coated part is identical to stock, down to the surface texture. The process we use to coat the handles also leaves a 100% stock finish... indistinguishable from the original. Unfortunately we will need to reach 65-70 people before being able to break even on the map cover. As the costs associated with producing this piece in low volume quantities are so high, our goal is simply to break even on this project. If we can fix the map pocket cover once and for all, then Dan and I are happy campers... income earned or not (though a couple free covers for our own cars would be welcome .

Long story short, the list is moving along steadily but we need more than double the people currently signed up to break even. So... if you guys want this to happen, please tell your friends and spread the word. This GB needs to run at the very least in the 60's-70's (or more)... but that means actual FD owners who will follow through, not just a name on the list.

Thanks for your support !
Heath

Old 03-13-11, 10:29 AM
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Old 03-13-11, 02:13 PM
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Do you have a price if the 60-70 people follow though? Just a estimate? Just wondering what not cheap is for a map pocket lid? Thanks
Old 03-13-11, 05:24 PM
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Originally Posted by FDcurt
Do you have a price if the 60-70 people follow though? Just a estimate? Just wondering what not cheap is for a map pocket lid? Thanks
We're aiming for $250. This is an estimate... it may be slightly lower, it may be slightly higher but that's our best guess at this point. As I said before, we are trying our best to produce these, and simply sell them at cost, or extremely close to it once shipping/PP fees/hardware are all included.
-Heath
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Old 03-14-11, 08:40 PM
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Old 03-15-11, 07:21 PM
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Old 03-15-11, 10:13 PM
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Actaully I may have to delete my name because I need the box AND lid (my hinge fitting is also broken on the box) - I understand this is strictly the lid
Old 03-16-11, 03:58 AM
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Updated. Please tell your buddies cause to make this happen we need more people on board. Again, the up front tooling costs for the process we are using is extremely expensive but makes identical reproductions... making quality low volume parts is not easy. Even with the goal of breaking even we need ~70 people after we add in the cost of machining, coating, hardware, paypal fees, packing/shipping


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Old 03-17-11, 03:01 PM
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I wanted to add that these, along with our door handles are made in the USA, at a state of the art foundry. Yes the price is slightly higher, but for the quality of the parts (and the fact that the money doesn't get shipped overseas and builds the US economy). In fact, all products currently manufactured by SBG are made in America!
-Heath
Old 03-20-11, 04:38 AM
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Originally Posted by rotormotor
updated. Please tell your buddies cause to make this happen we need more people on board. Again, the up front tooling costs for the process we are using is extremely expensive but makes identical reproductions... Making quality low volume parts is not easy. Even with the goal of breaking even we need ~70 people after we add in the cost of machining, coating, hardware, paypal fees, packing/shipping


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[/quote]
Old 03-21-11, 02:53 PM
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Here are a few pictures of our one-off prototype (raw). As mentioned before, the finished product will be made in 93 and 94 finishes, and offered raw or coated in our proprietary coating which is extremely durable, and identically matches the interior plastics (see example of handle below).

Raw -> click here
Coated -> click here

The good: My door (personally) is forever fixed

The bad: This is not a production piece. To create the tooling to reproduce these in large quantities is extremely expensive (many many thousands). It's still cheaper than plastic injection tooling but those parts are made in the thousands, not hundreds, or tens. As a result we need around 70 people on board to make a GB happen (at least)... this is for us to break even. At this point our intention is not to do this for profit, but to simply get enough members together to produce the tooling and sell it at cost for the GB members. We are looking at the $250-ish range before paypal, and shipping etc (with 70 members). If we have less interest, the additional cost would have to be distributed amongst the interested members which would drive the cost up considerably for each part.... so... we need more people to make this happen. If the numbers start increasing we can begin taking deposits or payments to put this piece in production.

Please pass the word along to FD buddies etc... with enough people we can make this happen!

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Old 03-22-11, 02:45 PM
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WOW that looks really good, I hope this really happens!
Old 03-22-11, 03:00 PM
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If this is going to cost more than 250, I will take myself off the list. It's just too much, I rather drive without the lid. Thanks!

-AzEKnightz
Old 03-22-11, 06:46 PM
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Old 03-22-11, 07:06 PM
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Originally Posted by AzEKnightz
If this is going to cost more than 250, I will take myself off the list. It's just too much, I rather drive without the lid. Thanks!

-AzEKnightz
It shouldn't.... we just need more people on board is the thing. $250 is conservative. The "competition" claims they will be selling them for ~$200 (and hard anodizing will not match the factory finish) and has yet to produce anything. We've got a track record for making perfectly fitting and perfectly matching pieces. Without numbers, our hands are tied and we can't make this piece.

Ask yourself, if company A) makes and sells a part at cost, and company B) Has the part produced over seas and insists on turning a profit on it.... are the parts equal? does quality suffer? Are their parts being machined for a specialized bolt to fix the problem caused by the roll pin and plastic pivot? Do they require you to reuse (if you even still have it) the plastic pivots on the ends?

I insist that everyone interested go to their own door box, take a look at the design, and then ask the questions needed to insure that the piece they are buying (or will buy) fixes the design flaws in the original piece. I've spend a lot of time with multiple broken door box lids and know what the design flaws are. The fix for this part is MUCH more involved than simply making an identical replica in aluminum.... seriously. Is company X going to address those design flaws? Roll pin, plastic pivots, shrinkage of 1mm per 4" linear casting (the piece is about 8" length, and will be ~2mm shorter if directly cast), and the finish.

Our part looks identical but will be (from a functionality standpoint) redesigned and fixed. In addition to the more expensive casting process to retain the factory look/finish, we are doing additional work behind the scenes to fix the flaws in this part. Our part (if we can get enough people together to make it at cost) will NOT be equal to the part from company X... I assure you
-Heath
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Old 03-23-11, 07:29 AM
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Old 03-23-11, 08:11 AM
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Old 03-23-11, 10:07 AM
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Old 03-23-11, 10:09 AM
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Sorry for the previous post I guess my page didnt load right with the updated list.
Old 03-26-11, 08:00 PM
  #73  
DRIVE THE ROTARY SPORTS

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ttt
Old 03-26-11, 08:27 PM
  #74  
RX-7's since 1980

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Old 03-27-11, 10:51 AM
  #75  
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