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Badge Relocation: My take on what Freakydeaky did ...


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#1 techboy

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Posted 13 December 2015 - 11:19 PM

So, let me start off by giving credit where credit is due.  A few weeks ago I was surfing around on here like I usually do reading various threads when I stumbled across freakdeaky's thread in the showroom.  One of the things he did was relocate that badge.  This is his picture below.

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I knew the minute I saw it I wanted to do it, but I didn't like how he cut all the way through the grille (see the thread to see what I'm talking about).  I wanted to preserve as much of the grille integrity as I could and somehow provide a really solid way to mount the badge in the grille.  

So, here's what I've come up with and what I've done so far:

First, I marked off 7 inches to cut off the middle horizontal piece.
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Cut it out with a dremel tool:
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Test fit the badge mounted to a piece of cardboard:
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Stole some of my kids Crayola air dry clay:
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Packed the upper part of the grille with clay in order to create a mold:
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That's how I left it at work on Friday.  Hopefully by tomorrow morning its dry and I can pop it.  My plan from here is to draw the profile shape in CAD and then use a 3-D printer to print the piece out in black ABS. I should be able epoxy that whole piece in place and create a nice solid mounting spot for the badge.  At least that's the plan ....
1988 Starion ESi-R ... crushed by a tree 10/31/11 - back from the dead 8/2016
1988 Conquest TSi ... current driver - sold to Bigjoe 6/2016
1987 Conquest Flatty ... F/S thread - sold 8/2014
1987 Conquest TSi ... parts car - sold to Coldscrip 12/2011
1999 Eclipse 4G63 ... heavily modified.
Feeback Thread | Motor rebuild thread | Restoration thread

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#2 importwarrior

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Posted 14 December 2015 - 06:28 AM

That actually looks great nice work!

B-71 87 TSI ~ RIP
Black 87 Starion ~ Mess SOLD!!!
Proud New 89 slightly Rusted Fiji Owner !!!

The Ark was built by amateurs , the Titanic was built by Professionals.


#3 pcristquester

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Posted 14 December 2015 - 08:49 AM

I saw that too and I really like it....just don't have the heart to cut a good grille up. If I had an extra that was damaged in an area where a badge would look good like that, sure why not
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#4 techboy

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Posted 14 December 2015 - 09:42 AM

Lol ... I actually saw the thread like 3 weeks ago.  I've been thinking about it ever since.  It just took me this long to muster up the balls to actually cut my otherwise perfect grille for the Starion.  I have another on my Quest, but it's not as nice as this one.

I think doing the same thing for "Conquest" might be tougher to center right and have it look good in relation to the flip-up headlight just b/c it's a longer word.  You'd need a badge from an earlier car too since the 88/89's were all decals.
1988 Starion ESi-R ... crushed by a tree 10/31/11 - back from the dead 8/2016
1988 Conquest TSi ... current driver - sold to Bigjoe 6/2016
1987 Conquest Flatty ... F/S thread - sold 8/2014
1987 Conquest TSi ... parts car - sold to Coldscrip 12/2011
1999 Eclipse 4G63 ... heavily modified.
Feeback Thread | Motor rebuild thread | Restoration thread

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#5 button

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Posted 14 December 2015 - 11:38 AM

IMHO. if you plan to 3d print one piece, why not make a whole badge.
Looks good though

Edited by button, 14 December 2015 - 11:39 AM.

-Jay

#6 Turbo Cary

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Posted 14 December 2015 - 03:03 PM

I'd buy an insert if you print an extra. I like it looks awesome

#7 techboy

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Posted 17 December 2015 - 09:31 PM

View Postbutton, on 14 December 2015 - 11:38 AM, said:

IMHO. if you plan to 3d print one piece, why not make a whole badge.
Looks good though

Do you mean "whole batch" ... not badge?  3D printing is not really a process where you produce in batches, it's more of a one-off process.

View PostTurbo Cary, on 14 December 2015 - 03:03 PM, said:

I'd buy an insert if you print an extra. I like it looks awesome

Not sure if I'll be able to do that or not.  I'm doing this at work, so I'm using company material.  I don't think they'd appreciate me using up the black abs and making a profit off it. :D  I'd consider buying a spool of abs myself and doing it that way if enough people where interested.  Even with that though, I'd have to do it when the machine is open,  3D printing is very slow.  This piece is 7 inches long and took just over 3 hours to print.
1988 Starion ESi-R ... crushed by a tree 10/31/11 - back from the dead 8/2016
1988 Conquest TSi ... current driver - sold to Bigjoe 6/2016
1987 Conquest Flatty ... F/S thread - sold 8/2014
1987 Conquest TSi ... parts car - sold to Coldscrip 12/2011
1999 Eclipse 4G63 ... heavily modified.
Feeback Thread | Motor rebuild thread | Restoration thread

Posted Image

#8 techboy

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Posted 17 December 2015 - 10:03 PM

On Monday after the clay dried all weekend I was able to pop to the mold out.  First thing I did was take a razor blade and cut it in half.

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Using that profile shape and a set of dial calipers I was able to draw up a CAD model of the shape.  Next, I used our laser to cut a few pieces out of acrylic and test fit to make sure I had the measurements of the profile correct.  I had to make a few revisions, but the final looked like this:
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Now it was time to print a prototype at a low density.  Here's our 30 thousand dollar printer:
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Here's the prototype on the platen a few hours later:
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Her she is:
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On the back side I had to account for a support rib that is on the grille.  I didn't feel like trying to dremel it out, it was easier just to design around it.  At the suggestion of fellow worker, I also added two inverted cones on the back, I'm planning to drill small holes in the back of the grille and then fill them with epoxy,  That way they'll act like fingers and it'll never be able to pop out.
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And, here's the prototype in place:
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Overall .... I'm very pleased with how this little project came out.  I got a bunch of hours into this thing.  I'll be printing the next one at a higher density in black which should make it just about unnoticeable to someone who doesn't know otherwise ... as I wrap up I'll continue to post of pics.

Edited by techboy, 17 December 2015 - 10:05 PM.

1988 Starion ESi-R ... crushed by a tree 10/31/11 - back from the dead 8/2016
1988 Conquest TSi ... current driver - sold to Bigjoe 6/2016
1987 Conquest Flatty ... F/S thread - sold 8/2014
1987 Conquest TSi ... parts car - sold to Coldscrip 12/2011
1999 Eclipse 4G63 ... heavily modified.
Feeback Thread | Motor rebuild thread | Restoration thread

Posted Image

#9 IntercooledFlatty

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Posted 22 December 2015 - 10:22 AM

nice....... PICS !
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          MOPAR POWERED

#10 techboy

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Posted 22 December 2015 - 10:50 PM

More pics.  

Here's the completed printed pc. in black abs.
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Here's the two holes I drilled in the back of the grille to line up with the holes in the mount.
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Epoxied and clamped in place.
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Done.
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I ordered some black acrylic that I will be mounting the badge to, and in turn mounting to the piece I've created.  I' still waiting for that to show up.  I think shipping is a little slow the holiday season.
1988 Starion ESi-R ... crushed by a tree 10/31/11 - back from the dead 8/2016
1988 Conquest TSi ... current driver - sold to Bigjoe 6/2016
1987 Conquest Flatty ... F/S thread - sold 8/2014
1987 Conquest TSi ... parts car - sold to Coldscrip 12/2011
1999 Eclipse 4G63 ... heavily modified.
Feeback Thread | Motor rebuild thread | Restoration thread

Posted Image

#11 importwarrior

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Posted 23 December 2015 - 08:32 AM

nice work!

B-71 87 TSI ~ RIP
Black 87 Starion ~ Mess SOLD!!!
Proud New 89 slightly Rusted Fiji Owner !!!

The Ark was built by amateurs , the Titanic was built by Professionals.


#12 MountainAIR

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Posted 23 December 2015 - 06:22 PM

No doubt. should look good when its all said and done... awesome vision man.

#13 button

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Posted 24 December 2015 - 11:06 PM

I meant badge.
But, yes, batch as well.
You can do many things to give a 3d printed product a professional finish.
If you digitize the whole assembly, it can be thingiversed
http://www.thingiver...h?q=starion&sa=
Then people can make their own. 3d printing is getting very economical. I have access to 3 if not 4 3d printers. No $30k ones or I'd make it pay for itself. ;)
-Jay

#14 techboy

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Posted 31 December 2015 - 09:11 AM

We have 2 Makerbots and two other cheaper ones as well that I can't remember the name of right now, but when we really want accuracy we go to the old-school big one I used for this project.
1988 Starion ESi-R ... crushed by a tree 10/31/11 - back from the dead 8/2016
1988 Conquest TSi ... current driver - sold to Bigjoe 6/2016
1987 Conquest Flatty ... F/S thread - sold 8/2014
1987 Conquest TSi ... parts car - sold to Coldscrip 12/2011
1999 Eclipse 4G63 ... heavily modified.
Feeback Thread | Motor rebuild thread | Restoration thread

Posted Image

#15 MountainAIR

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Posted 31 December 2015 - 10:42 AM

Man a conquest badge done in cursive or calligraphy would look shuper shweet lol

#16 techboy

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Posted 05 January 2016 - 10:38 PM

Alright, now that the holidays are over and it's back to work it was time to finish this up.  Laser cut a piece of 1/16" black plexiglas and test fit ...

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Looked good, so time to glue it and clamp it:

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Should be able to take the clamps off tomorrow, attach the badge and call it done.
1988 Starion ESi-R ... crushed by a tree 10/31/11 - back from the dead 8/2016
1988 Conquest TSi ... current driver - sold to Bigjoe 6/2016
1987 Conquest Flatty ... F/S thread - sold 8/2014
1987 Conquest TSi ... parts car - sold to Coldscrip 12/2011
1999 Eclipse 4G63 ... heavily modified.
Feeback Thread | Motor rebuild thread | Restoration thread

Posted Image

#17 techboy

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Posted 06 January 2016 - 10:39 PM

Finished it up today by mounting up the badge.  Finally done.

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If anyone is interested in attempting this and you have access to a 3d printer, I'd gladly share my file with you.  It's saved as a DXF, which should be compatible with most software.  Just hit me up with a pm and I'll email it to you.
1988 Starion ESi-R ... crushed by a tree 10/31/11 - back from the dead 8/2016
1988 Conquest TSi ... current driver - sold to Bigjoe 6/2016
1987 Conquest Flatty ... F/S thread - sold 8/2014
1987 Conquest TSi ... parts car - sold to Coldscrip 12/2011
1999 Eclipse 4G63 ... heavily modified.
Feeback Thread | Motor rebuild thread | Restoration thread

Posted Image

#18 D-VO

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Posted 07 January 2016 - 05:45 PM

You should be able to get reasonably close with a belt sander and a piece of Delrin or ABS on this. Problem is just knowing what the dimensions are.

Also, that printer is only $30k??? Damn, they have come way down since I bought one at my last job, but that one printed in color.

#19 pcristquester

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Posted 07 January 2016 - 09:55 PM

Really nice work and you do a great job with the pics and descriptions!
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#20 techboy

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Posted 07 January 2016 - 10:13 PM

View PostD-VO, on 07 January 2016 - 05:45 PM, said:

You should be able to get reasonably close with a belt sander and a piece of Delrin or ABS on this. Problem is just knowing what the dimensions are.

Also, that printer is only $30k??? Damn, they have come way down since I bought one at my last job, but that one printed in color.

You think that's cheap, you can get a MakerBot for $2000 on Amazon.  Now, I can tell you from personal experience they are not the greatest and machine reliability can be a bit suspect, but if you're just doing stupid fun stuff at home and not trying to use it in an industrial setting, they're not that bad.

View Postpcristquester, on 07 January 2016 - 09:55 PM, said:

Really nice work and you do a great job with the pics and descriptions!

Thanks!  I really appreciate it.  I love a good challenge, and this was fun to do.
1988 Starion ESi-R ... crushed by a tree 10/31/11 - back from the dead 8/2016
1988 Conquest TSi ... current driver - sold to Bigjoe 6/2016
1987 Conquest Flatty ... F/S thread - sold 8/2014
1987 Conquest TSi ... parts car - sold to Coldscrip 12/2011
1999 Eclipse 4G63 ... heavily modified.
Feeback Thread | Motor rebuild thread | Restoration thread

Posted Image




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