DIY - Vacuum Forming Box

© Mark Qvale - June, 2018

	New DIY Tool

Introduction

After doing hundreds of 3D prints for canopies, skids, shields, et., I decided to build my own Vacuum Forming box so I could get the weight dramatically down on some these parts. I did a pile of research and found many different styles and sizes but finally decided to simply take the things I liked in many pictures found on google and design my own. This then is my version.

Tools I Used

Besides the basic hand tools, these power tools helped immensly with keeping things sized and squared perfectly.

1. 10" Chop saw w/60 tooth carbide blade

2. Drill press

3. 10" Table saw

Parts & Pieces

Here is the complete parts list for this project. All dimensions and screw specs for this project are imperial (inches).

Cut List

Hardwood 3/4 x 2-3/4 x 11-1/2

Hardwood 3/4 x 3-1/4 x 24

Hardwood 3/4 x 3-1/4 x 11-1/5

Hardwood 5/8 x 1-1/2 x 2

Hardwood 3/4 x 2-3/4 x 10

Hardwood 3/4 x 2-3/4 x 10-1/8

Plywood 15/64 x 11-1/2 x 24

Plywood 15/64 x 11-1/2 x 14

Pine Laminate 1 x 8 x 10

Alum Flatbar 1/8 x 1 x 3-1/2

Alum Angle 1/16 x 1/2 x 1/2 x 14L

Alum Angle 1/16 x 1/2 x 1/2 x 10-1/2L

Alum Angle 1/16 x 1/2 x 1/2 x 9-1/2L

Alum Angle 1/16 x 1/2 x 1/2 x 11-1/4L

Wood Dowel 1/2D x 10-1/2L

Heat Box 2-3/4 x 10-3/16 x 8-7/16

Hardware

4x #8 x 1-1/4" wood Screws

12x #4 x 3/4" wood screws

4x #8-32 x 2" round head machine screws

5x #8-32 x 1" pan head machine screws

20x #6-32 x 3/8" flat head machine screws

8x #6-32 x 3/8" pan head machine screws

2x #12-24 x 3/4" button head machine screws

9x #8-32 hex nuts

28x #6-32 hex nuts

2x #12 nylok hex nuts

14x #8 flat washers

2x 3/16 x 3/8 x 3/16 nylon spacers

8x small steel flat corner brackets

Heater Components

Walmart Toaster Oven

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Base Build

Cut wood pieces and box build

Corner clamps

Box build

Box and top parts

Template for marking and drilling the vac holes

Frame Build

Aluminum frame components

Clamp frame corner detail

Main frame joint detail

Completed frames

Completed and mounted frames

Heat Box Build

Sheetmetal layout and cut

Completed heat box

Heat element mount detail

First Mold!

Wait for it!

What's that sucking sound?

A very light, near perfect replacement part!

VF51 VF52 VF53

See Also

TBA