RAMP UPDATE...........

So, I wish I could say that I have been relaxing and doing nothing. These Genesis ramps are proving to be extremely difficult to get a good consistent product. If you look closely at your originals, in the flat area toward the upper part of the ramp (where it mounts) you can see indentations that are actually on the underside. I have wondered if this is why they opted to paint them. Anyway, those indentations are caused by what is called a "plug". A plug is used in the forming process to assist in the actual forming. The design of these ramps requires that the forming process be assisted. The difficulty comes in trying to keep that "assistance" from showing. I have modeled these in both male and female molds and have gone back and forth several times. I have even tried forming them with 3/16" PETG, but the problem caused by the design simply won't allow them to be made without assistance. I came pretty close with today's test and have decided to modify yet again my machine to produce these. In today's test I used some screen to add texture to the flat top of the ramp as a means to minimize the effect of the plug. I have now decided to actually mechanically assist the plug process to insure consistency. I hope to have that done tomorrow. In the mean time here are some photos of the form I did today for the left ramp which show the texture I added... Let me know what you think about the texture.. My hope is to come up with a process where I won't need the texture, but I think it adds an interesting effect.

more to come.... Mark

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