Reproduction Hi Viz Masts

[Karl]

A possible solution might be to try and remanufacture the replica parts without them being a direct copy. Can you maybe alter the design so that you save on materials or simplify the construction process ?

Just my thoughts , but if you can manage to make something that fits the relevant hole, looks very similar but does the job perfectly well then that would be good enough  .

[danny7147]

I'm only really interested in making accurate reproduction that look authentic to give the parts supply a boost. I've got a dead C5 in my garden that has got a blanking plate over the rear light and looks awful, but the cost of parts far outweighs it's value which is what spurned the project. If I can get that old beast to the point where, using replica parts, people think it's original, then I'll be happy ;-)

[danny7147]

Quick update, first half of the silicone mould's now made, looking good so far! Also I finished making the two poles today and I have to admit that they came out far closer to the originals than I expected! I'm intending to sell the poles as part of the 'kit', but I can produce these seperately if anybody requires replacements for their own C5's.

As expected, the coating is a lighter grey, and the two poles that I have made are about 3 inches shorter than the originals, but I can make them to the same length as the originals for extra cost. They look fantastic, and having heat shrink like the originals will last a long time, especially compared to the 'painted' surfaces that I imagined them to have! They do, incidentally, fit really well as I've left a bare 4mm at the base which fits perfectly into the holes on my C5, but you may need to file the hole out slightly to accomodate your flag.

The cost for two poles at 50cm (shorter than original) will be £12.50 including UK postage, abroad will be slightly more.
The cost for two original length poles (measured directly against mine!) will be £20 including UK postage.

Apologies for the dodgy photos, but my C5 stays firmly in the dining room when there's bad weather around so I can't take better ones at the moment! 

Reproduction poles on C5


Reproduction on left showing size/colour difference against original


Close up showing heat shrink on reproduction pole

[Luke S]

Looking very good

[danny7147]

Thanks! Other than the colour, you'd really be hard pressed to tell the difference between these and originals, so now I'm keeping my fingers crossed for the flag... here's it so far!



The second half's just been poured so about another 3 days and we'll see the first complete one!

[pso-buzz]

Now that looks impressive!

[danny7147]

Thanks, it's going well so far so fingers crossed! Ironically the high viz mast is the easiest out of the parts to do as it's a fairly easy shape to make and now that the poles are done it should be a really good copy! The last problems I've got to try and solve with it now are how to keep the colour of the flags the same as it's only a 0.5% dye... literally 1ml difference would make one a totally different shade from another! And although I've now got high viz red and white sheets of A4, it's a fairly irregular shape so I need to try and make a template to get it cut right every time!

Really getting there though and I think that when they're complete it really will look very, very similar to an original at half the price  The poles cost a lot more than the flags!

[radiomarty]

Fantastic job - very impressed 

[dansretropod]

Excellent!  It looks as good as the original.  Keep it up!

[danny7147]

Thanks  The flag in the mould (to state the obvious!) is my one and not a replica, but I'm really pleased with how the poles have turned out... even that's a small step!

[Luke S]

Thanks! Other than the colour, you'd really be hard pressed to tell the difference between these and originals, so now I'm keeping my fingers crossed for the flag... here's it so far!



The second half's just been poured so about another 3 days and we'll see the first complete one!

Fantastic 

[Luke S]

Looks original

[kamilb1998]

That looks fantastic! 

[danny7147]

That is original, it was the mould around it I was doing a photo of lol

[KarlG]

That is original

Aren't you going to have threads on the plates?