Whelen crossbar endcap reproduction

[toon80]

Hello guys,

I have this Whelen bar that needs new endcaps, but since they are hard to find, me and my brother used a 3D printer to try and recreate them. They are white as of now but with the proper painting, they should come out looking quite alright.
Of course they will not be exact replicas, but for display bars, I think they will come out pretty enough.

 

[StEaLtH2]

Wow... that'll do quite nicely...
Good work

 

[2004p71]

very well done man

 

[kerry4951]

I am impressed. I recently was experimenting with the same thing. I actually bought two old metal cigarette tins on Ebay thinking they would work. I removed and used the flip top thin metal lids.They ended up being the exact length but about 1/4" too narrow. I even posted over on the Vintage Whelen FB page showing how they turned out. I was able to locate two original Crossbar end caps and bought them, but they are hard to find and you can expect to pay the price if you want to buy a set. Your idea is a great idea.

 

[kerry4951]

Let me know if you and your brother are willing to make anymore. I may be able to drum up some business for you. White would be fine as most guys doing these crossbars over already have the aluminum paint to use. Thanks

 

[toon80]

Hi Kerry,
Thanks for the compliments . We are running some thickness tests at the moment to try and come up with a model that is sturdy enough , yet not too thick .

You can actually see the multiple layers to make them. With paint I assume it will be better hidden.

They won't be as though as the originals of course but as I said before, I think they will suit just fine for cosmetic displays .

 

[toon80]

I will try to post a side by side original vs replica picture when we get the final settings figured out.

 

[kerry4951]

Hi Kerry,
Thanks for the compliments . We are running some thickness tests at the moment to try and come up with a model that is sturdy enough , yet not too thick .

You can actually see the multiple layers to make them. With paint I assume it will be better hidden.

They won't be as though as the originals of course but as I said before, I think they will suit just fine for cosmetic displays .

I agree with how sturdy that need to be. Most guys who are doing these Crossbars over are only using them for display. Keep up the great work!!

 

[dmathieu]

WOW! Very nice!!

 

[ex416]

good job. it appears to fit like a glove.

 

[Scoot163]

So much potential with 3D printers! Great project!

 

[Clarence H]

Let me know if you are going to produce some extras, I need a pair.
Clarence

 

[toon80]

Hi all,

Will let everybody know when spares be come available .

Thanks for the compliments everyone !

 

[kerry4951]

Any more progress on making sets of these for others. I just got a crossbar that could use a set.

 

[toon80]

The design I posted earlier in the thread remains almost the same so far. The question is how tight you want it to be.
For display purpose it can be a bit loose, but on a parade car it would most likely fall off unless you screw it to the bar.

If I make it too snug, it will hold and most probably delaminate quickly.

Let me know what purpose you need those for and I should be able to find a proper compromise.

New color can be light or dark gray. You can paint them as well to fit your needs I suppose.

 

[kerry4951]

I would only be using mine for display. Fitting a little loose would be fine. Either color would be fine because I would paint them anyway. When I restore a Crossbar I end up painting the accessory lights, the feet, and sometimes the bar so painting the end caps would be part of the restoration for me. Thanks for getting back to me and let me know what you can do.

 

[OliverD]

Nice job ; 3d printing, good idea ! thanks for sharing !