Comet center ramp update....

The molds are poured and are now curing which basically starts the clock on production. While I will do some finishing work on them as they cure, I do not expect them to be ready for actual ramp production until probably around the 10th to 12th of this month. Due to the geometry of this ramp, I will actually form them two at a time.....it's a yin/yang thing.

The donor ramp I was given was actually a very nice example with the only apparent damage being at the drop hole and that was just a crack in the end wall. This is very typical on ramps with drop holes that were originally formed on female molds as the heated plastic thins when pulled down into the ramp mold...in the case of Comet, it has thinned to less than 1/16". I've posted the photo below before of one of the Transporter ramps with this same type of thinning and how reverse molding to a male mold significantly increases the thickness of the formed plastic at the drop hole. Reverse forming will also strengthen the entrance at the bottom as well.

The original ramp has rolled over upper edges which are also the result of female forming. I expect my top edges to be either flat or just slightly curved over (Also shown in the attached Transporter ramp photos). It is difficult to uniformly get significantly rolled over edges like the original when forming on a male mold.

In addition to reverse forming this ramp for greater strength at the bottom of the ramp, I will also be increasing the thickness of the plastic by about 50%. This will result in the thickness of the entrance being quite a bit thicker than the original so I expect I will form two test ramps and then go back to my friend who has the game to test fit it. I do not want to sacrifice any of this greater thickness, so I expect worse case scenario would be that where the ramp fits down into the playfield might need to be increased in depth, probably <= 1/16...but in the end worth it for the greater strength.
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Weekday weather is just getting nice!...The weekend weather takes a little longer in Washington!

Sorry for the slow reply....sending PM now....

Yes you are on the list. Don't know how much the postage will be until I actually have the ramps. Whenever I can I try to ship in boxes no larger than 18" x 12" x 6" so I can ship First Class. Sometimes it's cheaper to ship in two smaller packages vs one larger package.

Yes... The molds are nearly ready for Comet, then I will likely make both the Demo Man and Radical ramp molds at the same time.

Larry... Do you happen to have molds for those?

Ah!.... Good news!

Thanks Larry.

With so many needed, the last thing we need is duplication of effort!

As I replied to your email, they will be narrowed going forward.

Been a while since I shot a photo of a ramp on the hot tub, but with the gorgeous sun out today....why not.

First test pull of the Comet Center ramp. Came out beautiful! This ramp will be hand finished then I will arrange for a test fit at my friend's shop.

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New Comet Center ramp #1.

I've finished the first test Center ramp and am awaiting contact with the donor so I can test fit.

Differences from the original....

*Ramp was reverse formed to address the thin plastic at the bottom of the ramp, most notably at the entrance and the exit drop hole.
*Plastic upgraded to .150"...Resulted in approximately a 35% increase in the weight of the ramp.

*See attached photos showing the effect of reverse forming has on the thickness at the bottom of the ramp on both the entrance and Drop hole.

*Original ramp has rolled over edges on the top of the ramp....basically a result of original female molding which also simplifies the "cut-out" from the form. You can see on many female molded ramps the rough saw cuts left behind. New ramp has smooth flat top edges.

While the increased thickness nicely addresses the inherent thinning at the drop hole, it also increases the thickness at the entrance which may result in the ramp entrance raised to the point where it will affect ball travel into the ramp. I could sand the bottom of the entrance down, but why sacrifice the increase thickness/durability? I will know for sure if this is an issue as soon as I can test fit the ramp in the game. If the ramp entrance is higher (honestly I expect it will be), upon installation, where the entrance meets the playfield, the "recess" in the playfield may need to be shaved slightly deeper to insure a smooth transition. Small price to pay for the added thickness.

Center Drop hole new (resized).JPGCenter Drop hole original (resized).JPGComet Center (resized).JPGComet entrance new (resized).JPGComet entrance original (resized).JPGNew Center bottom (resized).JPG

Well, I would not go that route. You're talking about sanding down the underside of the ramp to a consistent approximate 1/16" which at the back edge would transition to the thicker plastic, but at the edges of the part where the hold down screws are you will have lost the additional strength at the lower edges which again with a female molded ramp are typical failure points. I have the entrance metal protector for this donor ramp that was loaned to me and the leading edge of that protector is pretty hammered which indicates it is or was very close to the playfield level or even slightly above it. If I was to install, I would want that leading edge of the protector to be at or very slightly below the playfield level.

Too bad there is text on the playfield right in front of the ramp....I think a traditional flap might provide a smoother entry.

Just went and test fit the Comet Center ramp. Basically the fit was perfect and as expected the thickness of the bottom of the ramp will necessitate some minor work to deepen the recess under the ramp entrance. I have a little work to do to prepare both molds for forming so expect to begin the actual forming of the center ramps ramps by Sunday or Monday. After I've formed a bunch it will take me a couple days to set up the machining and then it will just be head down until I get everyone covered.

On another note, while at the donor's house for the Comet Center ramp, I also picked up the remaining pieces for Demo man....the car tunnel, the subway and the Cryo-Claw.

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Honestly, probably less work but I'd bet still some would be needed. I don't have a Comet to actually do the install so will be interested in someone who has confidence doing the install and making the necessary modifications to the playfield and be willing to share the experience.