Fred - I originally ordered a set because they looked cool. After seeing how they are made - jeez, they are incredible!!!

Jim

Thanks Jim! Trying to have them fit for Porsche cars that's for sure. 100% of those caps are made for good friends so a lot of care goes into making those things. Exclusive stuff so might as well have them looking good as much as looking cool :cheers:

Terry, certainly doable however, and don't take this wrongly, but I was hoping for you guys to use the template I've provided in an earlier post + a vector based software to do your own! Just so I don't have to go back & forth for draft approval, mods, etc, etc In any case, if you are not happy with the 'default' script, shoot me a PM and I'll see what I can do for you mate

Thanks for the kind words! Can;t say for sure if I'll have any left, to be honest it doesn;t look like it but you just never know... some may change their mind and I might end up with a spare or two ;) I'll post here for sure if that happens. Fingers crossed


In the Media this week:

http://986forum.com/forums/uploads02/011489717440.jpg

^ So the first milling Op on those center/centers is to face the back of them. Te lathe finishes the front surface, were the badge goes, but does leave a nasty finish on the backside. Ti fix this, we have to load them up by pair in the milling machine and take a light cut to get that mirror finish! Details... its all about details ;)


http://986forum.com/forums/uploads02/021489717460.jpg

^ So poor I can't even afford a decent workbench dedicated to the machines lolll This has to be the most ridiculous set-up of all time e.g. what happen if I bump in that skinny bar stool?! Time to get a nice table custom made I think...


http://986forum.com/forums/uploads02/031489717480.jpg

^ Adapters and centers are done!!! All left to do now if the main cap


http://986forum.com/forums/uploads02/041489717500.jpg

^ Kept a few center 'solid' so I can laser some of my mate's custom request/visuals. Can;t wait to get those Sepultura stars completed (see previous pages/renders, in black w/star).


http://986forum.com/forums/uploads02/051489717518.jpg

^ Preparing for this weekend's job (the main cap). Here I'm prototyping a precision thread that will accommodate the adapter. The adapters are
"deep freeze @ =22 degree Celsius prior assembly so this thread has to be right. No "lock-thigh & no-glue" on that thread. A plain a simple locking mechanism using thermal expansion (trade secrets, again!)

http://986forum.com/forums/uploads02/061489717538.jpg

^ Precision threading... had to made 5 diff size to find the correct one. So the aluminum cap has to be heated at 40 degree and the adapter deep-freeze for things to work. Once both parts are at room temp, its permanent... no way to get this unscrewed (got one chance at this loll)


Some Video:

<iframe width="800" height="450" src="https://www.youtube.com/embed/LUy9THxJujU?ecver=1" frameborder="0" allowfullscreen></iframe>


<iframe width="800" height="432" src="https://www.youtube.com/embed/mtqdcyfNj-s?ecver=1" frameborder="0" allowfullscreen></iframe>

:D

Thanks, please PM me if that is the case. Thanks again.

Hi Fred

I'll go with the default, haven;t really thought of anything better anyway!
Looking good!

Terry

Just joined the forum to comment here! :)

Man, this is amazing! The BEST center caps I have ever seen! Quality looks out of this world as well. Incredibly creative.

Do let us know if you plan to make another batch, or if you have a set left over.

It's been some time since the latest update on this. I everything alright, Fred?

No. Nothing is alright these days. Had my 'workstation' C drive (SSD) dying on me last Thursdayeve and spent like 4 full days just to get back on track. Also had a terrible cold/flu hitting me at the very same time. The End-of-The-World lolll

I'll push out the latest media news and answer PMs in a day or two. Let's hope my new camera lens has not melted while I was away.

Thanks for asking bud :cheers:

Feel better soon, Fred!

Sorry about your SSD and flu. I hope you were wise enough to have a proper backup solution in place, but judging by how you do things, it should be well taken care of. :)

So get well and get to work! ;)

Thanks Kevin :cheers: A cold virus... what's bloody worst than that (for a real man lol). Prefer road bike accidents over that nose pissing/sneezing thing anyday.

:cheers:

Yea got backup everywhere, mini-fireproof safe at home just for these sort of things and all. The M.2 SSD (oem) I got sent as replacement was the wrong size (day1). Restoring a 160G system image took 1.5 day because the external drive I have the system regularly backed up onto is encrypted and needed full decryption (using Truecrypt, not Microsoft). Then re-installing my latest system user defaults + software templates (+1 day). Add the sneezing and all that sleeping stuff; my work was blacked-out for nearly 4 full days.

Data backup or not, what a real pain. Never tough it would have happen (to ME anyway lolll)

Must be global cold/flu season, my whole house it right now, but I think we are finally on the tail end of it. Hope you are feeling better!

I think you're right, my whole house still has it...
(including myself, who hasn't been sick in years!):barf:

Take care and get well soon fellas!

Quick Update:
 

Ouch, already feeling better at least to know that I'm not alone lolll Get well soon fellas, this virus is by far the worst of all (in the lightweight virus category anyway).

Quick Update:

Good news; we are nearly there lolll I think we've done all the fixtures (jigs) that we needed to get these parts done to the tolerance we need (i.e. less than 0.05mm). IN fact, we did so well that most of the parts are ranging between 0.01~0.03mm. So... anything vibrating in your wheel I promise you its not The Great Porsche Center Caps - its the wheels themselves - or the road ;)

Some of you might think I am 'really' picky. The thing is I know for sure that some of my mates will drive their P car on the Int'l Circuit here in Shanghai and its a fast one (+320km/hr). As I know them well they just won't bother removing those caps so "they-have-to-work". Besides... I just don't want to end up being "the talk" at the track, not even for an afternoon!

So that precision/fit challenge is completed - finally lolll All we need to do now is 1,600+ holes and off they go to anodizing (this coming week).

In the Media this week:

http://986forum.com/forums/uploads02/011491006278.jpg

^ Looks weird, I know. Those are the precision threads I was talking about a week+ ago. The first turning operation for the main cap.


http://986forum.com/forums/uploads02/021491006300.jpg

^ Again! Needed a fixture done for turning the other side of the cap, the side facing the world. Parallelism, always... those two spacers made out of Acetal are also precision machined... and so is the fixture :/ Took me almost 1 day to make this item lolll


http://986forum.com/forums/uploads02/031491006321.jpg

^ More of the same, shows the rough piece of stock that precisely screw/thread on the fixture. Those same you saw on the green floor (pic 1)


http://986forum.com/forums/uploads02/041491006349.jpg

^ More of the same, again (not creative this week huh). That's what comes out of it. I'm attaching a Youtube vid below to show how this works.
Notice how violent the first operation removes the metal... that screw the cap thigh to the fixture and this is where those Acetal spacers comes handy! The only way to unlock this part after machining really.


http://986forum.com/forums/uploads02/051491006516.jpg

^ And finally, on the workbench. If all my parts would end up with quality surface finishes like this I'd do this everyday lolll Look sooo nice in person.


All the above, real-life!

<iframe width="800" height="450" src="https://www.youtube.com/embed/fX8YVjsJLME?ecver=1" frameborder="0" allowfullscreen></iframe>

Next:

Off to the final operation! 16 slots per cap, we have something like 115 to make. That should keep me busy for my entire Sunday night ;) I'll make a video of how this is machined using high speed toolpath. We have a high speed machine here so might as well use it to its real potential!


http://986forum.com/forums/uploads02/071491006705.jpg

^ Last (last!) fixture here. All geared up for Sunday... all what's left to do is pressing the "Cycle Go" button.


http://986forum.com/forums/uploads02/081491006715.jpg

^ Final product. DON'T PANIC; the product won't look silly shinny like this, no worries. The anodizing dulls the metal a little + color dyes makes them look & feel just perfect. Wait and See!


http://986forum.com/forums/uploads02/091491006724.jpg

^ And finally. Quite exited to see this on the workbench. Once the final operation (16slots) is completed, all we have left to do is anodizing and laser!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!


Beware - Sharp! Random pic. Because we can....


http://986forum.com/forums/uploads02/061491006791.jpg


I'll update in a few days - enjoy! :D

Even though I know I am not likely to get parts...I always look forward to your latest update. I learn so much by watching each step....Thanks so much for sharing. Its great to see and artist at work :-)

Winning comment of all time ( :cheers: ) - u r welcome. In that case, you can have mine bud. I'll be in touch

ps: one guy wants 4 sets here (Shanghai) and me have an idea of what he'$ up to. So bad news for him, he'll get 3 only loll Fair enough I think

hey, where you buy the crest from? I want to buy one of those for the car interior.
-Vidhu

Custom/made-to-order. The minimum order was brutal on those (so was the initial mold cost). Glad I'll get them all in use at the end :)

Bet you can find tons off eBay in similar size? E.g. shirt & cap pins. You might just need to dremel the back pin on one of those and you are all set. Just guessing out loud here

Beautiful work!! The results of high end machining is jewelry to me. What CAD platform do you use?

If you ever make another run I am definitely in.


Sent from my iPhone using Tapatalk

Looking good Fred, quite like the shiny, not for me though!

These look amazing, Fred, can't wait!

Quick update
 

Current CAD geometric modeling is parasolid, platform is Siemens NX. I also have/used SolidWorks but its been long unmaintained (unpaid) since 2+ years now. Prefer NX in all honesty, slightly more complex than SolidWorks but does a million things better at the end of the day.

No plan (as off now) for another production of those but if I ever do, I'll refer back to this thread and PM you bud. Let's see if we can get those 25+kits out first.

Wife actually mentioned when she saw that set arriving at home; "you're sure your friends will like that shinny thing?!". Luckily for us anodizing cuts off a good 25% reflection ;) Could look nice on a Bentley though, no?

Thanks bud! Me the first, quite anxious to have them all anodized and a kit snapped on my wheels :/

Quick Update:

http://986forum.com/forums/uploads02/011491522845.jpg

^ Last operation completed. Involves milling 16 side slots around the cap


http://986forum.com/forums/uploads02/021491522871.jpg

^ Makes for some great visual here. Shows all of the machined features of the main cap, thread, center bore, side slots, and the greasy Castrol coolant layer on top of them all loll


http://986forum.com/forums/uploads02/031491522901.jpg

^ Same caps, on the workbench after inspection. Each and every one of them went under the mic for tolerance checks. Reject=two only! Possibly due to some debris left over from the previous op (human error!)


http://986forum.com/forums/uploads02/041491522930.jpg

^ $200 worth of carbide end mills and inserts heading for the bin. They certainly did a great job. Some of those could be re-used but most machinists prefer fresh and sharp cutters when starting a new job ;) So... off they go!


http://986forum.com/forums/uploads02/051491522993.jpg

^ Garbage?! That's right, I am sharing with you what the garbage looks like after a job like that. Recycler-man loves those swarfs and so do I. I get $1 per KG of that stuff lolll You are looking at a fat $40 worth of garbage here!


http://986forum.com/forums/uploads02/061491523052.jpg

^ All packed up and sitting right next the shop's exit door. Heading down to my secret anodizing facility (anodizing is illegal in my area, can't be done at my shop or/at the cost of being fined quite a lot).


Quick vid ~ those were quite a lot of holes (thanks to Beats for providing great headphone (ear protection systems!)

<iframe width="800" height="450" src="https://www.youtube.com/embed/15AxNM0ArkA?ecver=1" frameborder="0" allowfullscreen></iframe>

NEXT:

Taking orders and Anodizing! I'll shoot a PM this Saturday to all who've shown interest in this thread, letting you know how to proceed for payment and what to expect! Would do this tomorrow but it's my dog's quarterly vet visit + I'm cooking for friends in the evening :/ Talk again this Sat, fellas!

Fred, you do absolutely amazing work! I really don't need center caps, I am actually happy with how mine wheels look, but I almost want to order a set just to display on my mantle! Seriously, you produce some beautiful stuff! :cheers:

All looking good Fred, I'll keep an eye out for your PM
Terry

This is looking better and better! :D
No PM yet, though... :(
Edit: I got a PM! :)

PM sent. Apologies for the delay.

Lovely weekend although pissing rain and cold. We've spent it all at the circuit (Chinese GP) and partied most of y'day with the organizers (early start at 19:00). Helen my wife is still sleeping now and its Monday 18:00 (ouch!). We came back at 04:30.

Love mosports ;)

And I've placed my order. :)
I didn't bother with the custom laser script, though. :P

And me order placed and paid. Can't wait to see them.

Sent from my ONE A2003 using Tapatalk

I'm in, thanks Fred, can't wait to get them on my car!

HI Fred,

Got the message just a quick question about the black centre, is the default just aluminium? If so I'll pay the extra 10 bucks and get it black.

Terry

@Rob and @Paul
Thanks fellas, well received!

Haha, it works!!! That extra $25 was to discourage anyone who wanted to get this laser job custom loll The more custom jobs we have to do = the longer it takes for everyone to get their caps (I'm one of those that wants them soon'er loll)

However yours looks fairly easy so if you are happy to wait after I've shipped out the standard kits, I'll get the custom laser done on yours no extra cost bud. Already agreed to in a previous post (I think). Let me know if that's okay with you (e.g. +3~4 days, not the end of the world)

Terry, you are correct. The default is clear anodized on the center, therefore silver color. If you want them all black that's going to cost ya! The little Anocalc I have here compute $1.60 for each center in black anodized (the dye, seriously). Thought I'd raise that to $2.5 each (2.5 sounds better loll)

At that rate I should become billionaire in 287years; there some ambitious life goal :D

Just ordered a fresh/backup of black dye from Japan a week ago. TAC: 1KG=$620... to give you an idea :/

Why, you... [emoji16]
Thanks a million for offering. I actually think I prefer them without any laser script at all, though, if that's not too much work. [emoji6]

In fact, I ought to get them cheaper that way... [emoji14]

No-No cheap here bud, I wish (sincerely). Would you believe we've estimated that roughly 65hrs went into making the fixtures and programing. Not accounting for the CAD and validation (CAE) of the models (that's extra). Just for a 20x manufacture-prep-run, and at my hourly rate, you are looking at a >$600 kit there lolll

Gift for you: The Best-in-the-World Porsche 'stick' LOL I'm soon going to make this FREE for you to download (on request only). Sort of an opportunity for any of you to become a manufacturer for one day! Model can be sent to your nearest 3D printing, you get to do the surface treatment and detail it with some super-duper expansive metallic paint. Recommend 'metal' 3D printing, makes it easier to polish afterward ;)

Personal/hobby use only; can't be sold. That is actually a very expansive Porsche item ($900 if I'm not mistaken).

http://986forum.com/forums/uploads02/011491904579.jpg

^ The one without the 1-2-3-4-5-6-R hat is for the Tiptronic. The one that goes in my car lolll


http://986forum.com/forums/uploads02/021491904039.jpg

^ This is 'surface' modeling. All driven with industry standard G1~G2 curves and I think I have 2 or 3 splines in there that are G3 continuity. Expansive stuff :/


http://986forum.com/forums/uploads02/031491904050.jpg

^ Career for the less-than-sane individuals - don't try this at home :D

I believe you, and I wasn't being serious. :)

Of course not, brother. Its allll part of the show, remember :cheers:

Thanks Fred, will pay that today.

Terry

Sent you an email fred

Now paid

Terry

Terry, confirmed mate, just saw that. Oh man you will love those blk-on-blk. We'll have the same, that is what goes on my wheels here also (friends for life loll)

3 kits left (so sad) :/ Just waiting for the 3 remaining members who've I've promised those too. We'll give them until this coming weekend before they go to someone else ;)

@Martin - reserving a kit for you bud (and pls don't forget my msg for your bro)

Is it too late to get in on these? They are nothing short of fantastic and the price more than reasonable.