Seek help - sort of duck related

[Mark W]

I am working on a new project and have come across an age old problem I can figure out. I am working on adding something to a pair of earmuffs but need a flat place to mount it. When wearing nice earmuffs. the plastic cup has a curve from front to back. Earmuffs measure about 4" width wise. I need to make a device (balsa, plastic - doesn't matter) to match the curve of the earmuff and have a flat surface on the side not attached to the muff.

I intend to mount this piece to the earmuff using VHB double sided tape and so the piece doesn't have to fit exactly correct as the foam tape can fill in some deviation.

I know there is a tool that I can get that will measure the contour but hoping their is a tooless way to do so. I know there is the trial and error method of cutting cardboard or paper a little at a time until the shape you need is met.

Thanks all. I know someone on here knows how to do this.

Thanks -

Mark

 

[Carl]

Sounds to me like you need a scribe, a piece of cardboard and a very steady hand to trace the curve.

 

[Dani]

Sounds to me like you need a scribe, a piece of cardboard and a very steady hand to trace the curve.

This.....

Another option is to take a picture of the muffs and print it out at real life size (black and white printed photos tend to be less distracting when doing this) and then cut out the muffs from the picture and use that as a pattern.

 

[Huntindave McCann]

I need to make a device (balsa, plastic - doesn't matter) to match the curve of the earmuff and have a flat surface on the side not attached to the muff.

I intend to mount this piece to the earmuff using VHB double sided tape and so the piece doesn't have to fit exactly correct as the foam tape can fill in some deviation.


Mark

I might suggest a JB Weld product. KwikWood Epoxy Putty - 1oz | J-B Weld (jbweld.com) or WaterWeld Epoxy Putty | J-B Weld (jbweld.com)

Either one comes in a "putty" consistency so can be molded to fit the contour as it it pressed against the earmuffs, while the opposite side of the glob of putty can be tooled flat. If needed the "flat side" can be sanded of filed, even flatter after curing.

To keep the JB Weld putty from adhering directly to the earmuffs, first cover the surface with a layer of packing tape, which will serve as a release agent. Then your chunk of cured putty becomes your custom molded spacer, which can be attached with the double side tape.

The "KwikWood putty has a tensil strength of 900 psi while the "WaterWeld putty has a 1300psi tensil strength. Both products have a 15 -20 minute working time.

Sound doable or do I have you totally confused? NOTE***** try this on a test piece of packing tape to confirm the putty releases once cured.

 

[Mark W]

Thanks for the ideas.

I also found an earmuff that is flat (Walker low profile passive). While it has a flat place to mount what I am looking for, they aren't very comfortable muffs and I can't see wearing them for 3-4 hours at a crack. The other issue with these is they say 31 db reduction in the ads and the pacakge says 22 db's. Considering each 3 db is is doubling of sound, 10 db's make a difference.

Forgot to mention this mounting plate needs to be very lightweight as what I'm putting on the side has a little weight to it.

Mark

 

[gcs]

Know anyone with a 3D printer?

They can model what you want and print it with one of the plastics.