I will tell nothing - you can torture me all you want!

Seriously, new prototype (and let's hope the last) is under construction now, should be done early next week. We moved the V back .200", adjusted the top fit to wedge better, and made a couple other minor adjustments to everything. I think this will be it, then we go into tool production. It stinks that we're always catching stuff in the prototype phase that has to be corrected before production, but it's better than catching it after production pieces are in the field...

So in short, it's moving along just as expected, with just a couple small bumps in the road.

 

When do you expect the first orders to be shipped? I'm ready to order now!

 

Late August at the rate we are moving, but it might move into September or so based on things outside of our control. Once tool build starts, it has to go at a relatively slow pace to insure the finished part looks good - it only can be as good as the tool it was created from.

 

Marcello,

This product is great and thanks for all of your help. I work for a plastics company, so I'm curious. I assume this will be injection molded, but what material will you be using, an ABS, PC, PC/ABS or a more robust PC/PBT? Or a Nylon of some type? Thanks, sorry for the geeky question, but us Plastic Guys! Thanks again for the great products.

John,
SABIC Innovative Plastics (formerly GE Plastics) - makers of Lexan*, Cycolac*, Cycoloy* and Xenoy* Resins, amonst many others...

 

No sweat, there aren't any geeky / stupid questions (well, yeah there are, but you're supposed to be nice !!)

Anyway, like our honeycomb panel and our GT inserts, we will be using UV stabilized ASA resin for this piece. The resilience, strength, and sun resistance we've seen with it in our other products makes it a perfect candidate for this piece as well, while at the same time helping to contain costs by being able to buy in a larger quantity of resin even as costs on the resins continue to increase on us.

As to production - we'll be working on a 300 ton Van Dorn press, and the tool is a steel frame with aluminum inserts, looking like a single gate shot. Because of the design on this piece, unlike the the GT inserts, we should not need to incorporate any slides or additional mechanics in the tool itself.

How's that?

 

Very cool. Thanks for the great answer. And an ASA is an even better choice becuase of its UV Stability and Color Retention. And you can get high or low gloss in a variety of colors if you choose to do a molded-in-color other than black for other operations. Our ASA is Geloy* resin. Do you buy from SABIC, BASF, Bayer or through a distributor. Just asking, I'm not a saleman. I'm in Communications.

 

We use BASF for the ASA, no need to mess around for a few pennies when you know you can get consistent results from a known supplier. It's the same reason we use 3M for a lot of our chemical stuff - it's just not worth the potential problems to use anything less. And because of our relatively low volumes (one or two ******** does not make for a volume production...) we normally go through a local distributor for the raw material. 3M does sell in small quantity to us though, so we buy from them directly.

 

Consistency is the name of the game when you're molding plastic! And using those quality products helps you make quality product that we get to enjoy. Thanks for everything you do. I'm looking forward to the insert. I just bought a Cali front end for my car and I plan on installing your new insert when I install the fascia! Thanks again.

 

Title says it all I think

The prototype that we just finished playing with today is absolutely awesome, that's about the best way to describe it. I'll work on some installed photos, but suffice it to say that ALL the concerns have been addressed, and with the 1 minute install we have designed, it just doesn't get any better. Fit and finish will be nice, strength is really good given the shape and design of the part, and it should do an excellent job of protecting the radiator and condenser / intercoolers on everyone's Mustangs.

Now that we're 100% sure of the final part, mold base (about a 1.5 ton base) goes on order next week. Once it arrives, machining will begin on it, followed by sampling, then production. Not sure about August at this point due to the fact that next week is July already, but it is "fast track" for prodcution with nothing I can see to slow us down until it is done. There aren't any weird gates, slides, or other issues to contend with like some of our other products have had, which add time at the end of the tool build, but who knows, we'll see how it comes out.

Just know that the "hard" part is over, from here on in, it is pretty much a standard process that just needs to be done step-by-step to get to the finished product for everyone. I think everyone willing to wait will have their patience rewarded with a nice, U.S. made finishing touch for their GT/CS and Shelby GT cars.

 

Oh man I can't freakin' wait. Thank You Marcello you are the Mustang Man.

 

Thank you Marcello!! Your products are the best, and you are the man!!! Can't wait to order the part when it becomes available!!!

 

Thank you Marcello.

 

Sir Marcello: Just revisted this thread for an update on the lower grill progress. Sounds as if my own ( post #32 here) and everyone elses wishes/desires for a new GT/CS lower grill are going to be granted! Thanks Bro, to you and all your great engineering staff. For bringing yet another dream to life!! You guys are the best!! Your products set the high water mark for Quality production! Will be ordering this new part along with everyone else, as soon as they hit the market! Thanks again Sir. "RC"

 

I just put my GT/CS bumpers on, so a lower grille to finish it off will be excellent.

 

Thanks guys

I'm not sure how to best photograph this so everyone can see how nice this piece fits and works, so I might do it a couple different ways, then work with the images to make them visible via web compression. In the meantime, everyone who has seen it in person has been impressed. The fit is as good as our GT inserts, which we had factory CAD files for! But the fact that the GT/CS "needs" this so much more than the GT makes this piece all that much better.

In the photos, I'm going to show the comparison between prototypes as well, so hopefully everyone can see how the pieces develop from initial idea to finished production pieces.

Now just a little patience as we get through the tool build process, and everyone will be good to go!

 

when do you think we can expect these pictures? im extremely excited to see the final product. it puts me that much closer to placing my order!

 

From the local news:

While taking pictures today to show the difference between prototype #2 and #3 for potential clients, #2 had an unfortunate encounter with the tile floor in the front shop. While no injuries were reported, it was said that Marcello did want to throw his SLR camera across the room because it was cheaper than the prototype that just "got busted up". Luckily prototype #3 (the final one) was undamaged in the incident.

Pictures though might be up tomorrow if I get a chance to play with them in PS for everyone. I will say that it seems I am careful with the prototypes all the way up until I know I don't "have" to have them anymore, then they tend to get banged up - happened to the Honeycomb panel, the louver, and now this... only the GT inserts didn't get broken yet, and they are so small I don't think dropping them would do it... although I'm sure at some point I'll get a chance to find out.

Ugghh... I hate myself some days!

 

Marcello I can't wait to order these and put them on with the A47 mirrors and the fuel door and rear emblem your sending me.

 

Marcello, if you want to send me the photos, I can tweak them for you. RAW would be best, but if you only have JPG, I can do that, too.

Here's a new GT one.

 

Humm I think I'll be needing one as well