I need help choosing a material.

[SpookyDad]

I make reproduction antique radio face plates. I have been making them out of MDF but I am concerned about long term durability. They are subjected occasionally to the wet weather and I am worried they will distort even after painting.

I am considering changing to some sort of plastic. Other materials are a possibility, just have to keep cost in mind. The originals are cast pot metal or machined aluminum. I have a Joes2005 woodworking machine so I would rather not machine them out of aluminum.

Here is a couple of pictures:


http://i13.photobucket.com/albums/a2...efaceplate.jpg

http://i13.photobucket.com/albums/a2...s/IMG_0510.jpg

[bobsch]

How about Bakelite? Many early electronics used Bakelite cases.

http://www.professionalplastics.com/BAKELITE

[cpcp]

Coating MDF properly will prevent entry of moisture even when permanently exposed to the elements (boat-building excepted!) The original materials you mentioned would give something of a satin to rough finish so a few coats of varnish/sealant should replicate it quite well.

Looking for a plastic that is as soft to machine as MDF and simultaneously as rigid and not as water absorbent will be a challenge.

[ImanCarrot]

Mylar would do it: nice colour and machines beautifuly: nice and soft but not "gummy".

It smells of fish though when you machine it- have a shower before you go down the pub!

[SpookyDad]

I check out Bakelite, WAY too expensive. Bakelight was used for a lot of radio equipment, mostly field telephones, but it was cast under pressure.

Painting the MDF is what I am doing now. The problem I have found with MDF is when you are carving small text, the insode of the "O", "B", etc tends to flake off. Perhaps I am doing something wrong. (I use a Porter Cable router.)

Mylar sounds interesting. I will have to investigate prices and local availability.

I had some labels made for the knobs and dials using a laser. They came out crisp but no depth at all. I had the company re-do them by going over the letters twice, better but not really good. They are redoing them again but only under protest. So that isn't really an option.

Neil

[awerby]

What about Masonite? It's harder and more fine-grained than MDF, but shouldn't be a problem to machine on your equipment. The tempered Masonite is more impervious, but there are some issues with how it takes paint.

Andrew Werby
www.computersculpture.com