RS Front Turn Signal Alternatives? I'm at a loss.

[The Mighty Gryphon]

The Chinese have no interest in anything that is not generic, fuel pumps, filters, etc.  Anything model specific won't be of interest to them, unless it is something like those 175cc machines that are so prolific in S.E. Asia.  And maybe even those won't interest them.

The only solution I see is short run prototype injection molding with unhardened aluminum tooling.  This process is advertised as being cost effective for runs as short as a couple hundred parts.  Of course, as Bill Clinton so famously said, it depends on the meaning of "cost effective".

The biggest hurdle I see is getting a digital file of the lens that can be used in a cnc machine to create the mold cavity.  That is the part of the process I have no knowledge of.  It does appear from advertising I have seen for modern dental work that there are ways of mapping a 3 dimensional object and creating another object from the map, so I guess the technology is there. 

Does anyone here have any experience with 3D mapping?  That would be the starting point for getting a price to make parts.

[Motorhobo]

That was also discussed by the Flying Brickers but 3D mapping seems to be more complex than anyone wanted to take a stab at. Easier would be 3D modeling a reasonable facsimile -- I could do that but don't have an RS -- it's got to be someone with skin in the game.

[Laitch]

I could do that but don't have an RS -- it's got to be someone with skin in the game.

Another stake has just been pounded into the heart of altruism.

[BrickMW]

A thought came to mind.. I have a friend that uses a 3d printer and a CNC laser cutter to make custom personal vaporizers, (Google Friendly Fire Mods for pics) he uses the printer to build up the edges and internals then etches and cuts the side panels with the laser.
Why not try that with these lenses? Print a ring basically converting the mount to a flat plane or 2 angle (tent ^) surfaces, then glue a piece of lexan to it. Color and opacity of the ring could be anything and the lexan would be crystal clear amber and easy to form a straight line "tent" bend on a small to medium radius.
Still involves the 3d mapping and modeling to make it happen, but could prove to be a more viable alternative to printing the entire lenses.
Basically make one of these...


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[The Mighty Gryphon]

I am contacting these guys for a price estimate to map a pair of RS lenses. 

https://www.laserdesign.com/

With a map of the lenses I hope to be able to get a quote to build tooling for a short(100 to 1000) part injection molding prototype production run. 

I have yet to contact a molder about tooling requirements.  My concern is that prototype tooling may not be up to the task of processing to achieve the required optical properties.  Another very large concern is that these lenses will require DOT certification.  As anyone who has had the misfortune of having to deal with bureaucrats knows, this would be a deal breaker.

Don't get your hopes up too high.  This is a side project and I don't have a lot of time to pursue it.  It could be a couple months before I can say if this can be a feasible route to replacement lenses.  The only good news I see is that BMW's stupid pricing provides a real opportunity to create a cost competetive alternative source for these lenses. 

[The Mighty Gryphon]

Update: I have gotten a response from the mapping guys, and I have a ballpark number for mapping.  I will be sending part photos later today for a firm quote.

To get files suitable for creating injection molding tooling for both lenses it will cost between $900 and $1300. 

Next step is to see what it would cost to make tooling.  It's been a long time since I was in the business, so I will need to talk to some people. 

Motorhobo, how many of the German guys need lenses?  How much would they pay?  I am pretty sure I can hit BMWNA's stupid price point or maybe even beat it by a little.

Stay tuned...

[Motorhobo]

I just replied but the reply disappeared -- I hate that.

Anyway, I did put out the request for info but I suspect the DOT thing is a deal breaker both here and there. No DOT stamp == big fine. Maybe an individual user might get under the radar with a one-off 3D print, but mass producing safety-related parts without DOT approval? I'll come visit you in Alcatraz!

[The Mighty Gryphon]

Actually it would probably be the Federal prison in Warren PA.   I had a friend who's brother got sent there.  At my age it would actually be rather nice.  More activities than a nursing home(tennis, basketball, swimming pool) excellent health care, decent food, and it's FREE!

As far as DOT, I will check into that as well.  It may just apply to the original design.  There are lots of people making replacement lenses for classic cars.  I wonder how they handle DOT?

[Motorhobo]

Actually it would probably be the Federal prison in Warren PA.   I had a friend who's brother got sent there.  At my age it would actually be rather nice.  More activities than a nursing home(tennis, basketball, swimming pool) excellent health care, decent food, and it's FREE!

Yes, and I hear they give a choice of companion in your cell -- either your dog or your motorcycle!

[The Mighty Gryphon]

Cell???  This is a white collar facility.  My understanding is that you are held in cabins.  The only real security is a perimeter fence to keep freeloaders out.

[Motorhobo]

Seriously? OK, then dog AND motorcycle, but by popular consensus, wife is persona non grata...wives would just spoil the fun!

[Motorhobo]

So to close this issue out, the Flying Bricks went through this whole line of inquiry last year and marked the thread as 'Closed' -- nobody's interested in taking any action to independently produce this part because 1) of the rumor that the OEM part will go into afterproduction soon based on the original OEM mold and 2) the likelyhood that the part will be produced on an as-needed basis soon in 3D print production and 3) lack of hard data about whether there's enough demand to justify the investment and lack of interest in taking the time to collect the aforementioned data.

So if it were me I'd do the 3D thing or try to make a fiberglass mold or do some mod of some other aftermarket signal thing -- but I wouldn't hold my breath for an aftermarket production run.

[The Mighty Gryphon]

I agree, it would take years to get back an investment in tooling and machine time. 

Best advice is to remove the OEM mirrors and replace them with some nice looking aftermarket turn signals and mirrors.  I know there is at least one bike out there that has been down that road, and really, it looked pretty good. 

Not only can this option look good, these aftermarket parts are out there at prices such that you could replace both mirrors and turn signals for less than the price of a used mirror glass.