Plastics to make an instrument pod

[Norman_E]

I need to make a larger instrument pod to replace one made of fairly thin plastic. My plan is to build it from plastic sheet material 6 or 8 mm thick, with the edges made from much thicker material, so that I can round all the corners with a router.
I have found a supplier here with a choice of nylon, delrin & acetal materials. I need something that will machine, and can be welded with a suitable solvent.
Does anyone know what I should choose, and what solvent will weld it.

 

[chuzzlewit]

DIY in GRP?

 

[Juggler7823]

Take a look at Jan PBO for a GRP solution. There are probably easier ways than making a wooden plug for the mould look around at tupperware boxes etc

 

[davidwf]

Somone once suggested a pod made from a taxi sign, there seems to be loads of different types available.

see Txi pods may be better suited for over the hatch garage though.

 

[Norman_E]

I thought of GRP and read the article but I really don't want to do it that way as my pod is to replace one that is rectangular, with no taper from front to back, so a box made from thick plastic sheet is a better solution.

 

[oldsaltoz]

You could make your pod with thin core material like ply or klegacell and fibreglass over that then fair it for the perfect finish and shape-size of your choice.

Avagoodweekend......

 

[lille_bee]

We used a large white plastic chopping board that we bought in a hardware shop... cuts, saws, routers perfectly, doesn't rot, cheap and easy to find...

 

[Norman_E]

Thank you for that idea. I had wondered if they were suitable, and I will see if I can get them big enough. I guess they are made of nylon or polypropylene.

 

[lille_bee]

Amazon sell one that's 42 x 28 cm, polyethylene:
http://www.amazon.co.uk/T-ANTI-BACT-CHOPPING-POLYETHYLENE-420x280x12mm/dp/B00022M3LA