Date:         Thu, 22 Mar 2007 13:48:04 -0500
Reply-To:     John Rodgers <inua@CHARTER.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         John Rodgers <inua@CHARTER.NET>
Subject:      Projekzwo Lower Grille Fog Lights - Kit Update
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Last year I undertook the task of trying to get replacements for these
grilles since they went out of production. I was over taken by a bunch
of health issues and the project  got put on the back burner. Initially
the plan was that I would build molds and run these on my vacuum forming
machine. I cannot do that now because of the effects of eye surgery on
my retinas. Simply can't see well enough to do that kind of work.

SO!  I took the two pieces I have been loaned to a company who does such
things and they had a look. After a bit of study, they came up with an
R&D cost of about $2000 to build the mold. After that front end cost,
the grille pieces - 1 right and 1 left - could be produced for between
$30 and $50 a pair, depending on how many pieces were made in a
production run. No hardware cost - ie, lights, bulbs, screws, brackets,
wire, connectors, etc - are included in those figures. From my own mold
making experience, the mold cost is pretty much right on, as half of
that cost is the mold-making material itself - a huge block of
polyurethane rubber, and a big wad of epoxy. There is roughly $500 in a
special jig for CNC trimming after each piece is made, and there is
approximately $500 in labor.

We would need a bunch of folks that wanted these in order to get the
per-unit cost down. If we have enough, we can get the lower price of $30
per pair, and we can spread the cost of the mold over how many pairs are
bought. Like if 40 people bought in, that would be $50 per person for
mold cost, plus $30 for the Grille pair - total $80 for the bare set.
Hardware would have to be a separate issue. I don't know what these
things cost initially from factory but it may be possible to get them
way below that factory price, including hardware. Finding the right
hardware source will take the effort of everyone.

Please thrash this out, and speak your mind on this thread. It will come
to a vote of yea or nay in the near future.

BTW, there is nothing in this for me. I'm just doing it for funzzies!!

Thanks,

Regards,

John Rodgers
88 GL Driver