Working with styrene
There are a few things to keep in mind when working with styrene. First think about your approach and second make templates out of card stock that is a similar thickness. This helps to ensure you get a good fit and don’t waist material. use thick cereal boxes or the like.
I have my template but didn’t make it using quite the right thickness of material. This lead to parts needing trimming and some warping. No big deal, nothing I can’t fix or hide with trim or some carpet. I used model cement to fuse the styrene pieces and then used Krazy glue (Kragle to the LEGO fans out there) to add another layer of strength. Don’t know that it will do much good but the tray is very solid now.
This image shows the tray with puttied edges. I used Tamiya putty. it took the majority of a tube to do the whole tray but now it is sealed to my liking and has a nice edge fillet. When I go to make my 3D printed components I can just trim away the edge where needed. This also added to the strength of the tray considerably.
As mentioned, here is where the template material thickness issue bit me. You can see some slight warping and flex in the bed piece, the photo makes it look worse than it actually is. Once the interior has more detail to look at it will disappear. I’m making a bed floor that will cover the hole for the suspension uprights for the most part. Pay no mind to the spur gear cover sticking through the centre console. I plan to cover it with an arm rest, lip down cushion between the chairs or maybe a sub woofer box.
After assembly and putty, I painted the bottom black. Similar to painting a body, I washed the tray in soapy hot water and gave a bit of a scrub to the areas I could touch. It closes off the volume of the body perfectly. It fits just right and doesn’t influence the body shape. At this stage with the relocated electronics and completed base tray, there is enough room for all the 3D printed interior trimmings now.
Here is a picture go the tray alone. It sits nice and snug on the chassis and doesn’t move at all. A perfect fit.