So I've been working on making a few of my own Pepsi perfect bottles and have been working on them for what seems like forever but due to work etc they have taken me a lot longer than id like to admit. Although its always been my aim to get these bottles as screen accurate as possibly could be. I want to say early on though I could never have got anywhere near accurate if it wasn't for the buck profile that Gary Weaver posted that was taken from his original production used Diet Pepsi bottle and measurements that Emma in Candyland shared with me from her original Slice bottle.
Although I have done a hell of a lot of research into each element of the bottle to try and get it right, looking a basically ever photo that has ever been posted of the production used bottles. And there was a lot of trail and error when it came to Vacuum forming the clear bottles but I won't really go into all that because it would take way to long. Haha
I started of by making my own Vacuum form buck using Garys profile of the original bottle, I made a 3D model of the exact shape and had it printed. I had original tried making the buck on a lathe and although I could get it close to accurate it just wasn't as close as I wanted.
Heres a few photo of my buck against a printout of Gary's tracing, you can just see the outline at the edge of the buck, I think its as spot on as you could ever get it!
Here I have offset it slightly to show the profiles side by side.
And here I drew around half of the profile in red pen to show how well it matches up.
This is the polished buck just before it got moulded.
I then moulded and cast two bucks ready for vacuum forming. I knew my master was the exact size that I wanted it to be so to avoid any shrinkage and also to help thermally when it came to vacuum forming I cast the bucks out with a mix of resin and aluminium powder.
It took me a looong as time to figure out the kinks when it came to getting good vacuum form pulls with good clarity but after buying a Ionized air gun the clarity in the pull was as good as I could possibly be for a vac form
I then trimmed the forms and then the hardest part of all came.
Gluing!!! I really have to give it to Gary Weaver. There is no easy way to make these bottle and have them screen accurate and gluing these things is not an easy task to figure out.
But I got there!
I also made some white pulls to make the Diet Pepsi bottle.
I then set out to make the flip up straw, I used exact measurements taken from emma's bottle. The rubber straw that runs through the middle of the bottle took me an extremely long time to find and get my hands on. It made it even harder that I am in the UK and the measurement of straw are in imperial so I had to order it from the US but I finally found the exact one.
The underside of the straw and how the ridge clear straw that rounds down the inside of the bottle where just as important to me to get right. There are not many photos of the underside for obvious reason that its hard to see. You can clearly see here how the original was constructed. Gary also posted photos of his production used bottle were you can see this much more clearly but I don't want to use his photo with out permission.
I quickly made up a prototype bottle with all the bits i have so far just to see how it looks and here it is. I haven't glued in the rigid straw that runs down the middle here so thats why its off to one side and obviously I still need to get Vinyl labels made etc. Sorry for the bad lighting.
Let me know what use think. I do plan on selling a few so if anyone is interested let me know. I will be posting more as I get further on with the project.
Downfall.
I have started and interest thread so please head over there to find out more, https://www.therpf.com/showthread.ph...69#post4394869
Although I have done a hell of a lot of research into each element of the bottle to try and get it right, looking a basically ever photo that has ever been posted of the production used bottles. And there was a lot of trail and error when it came to Vacuum forming the clear bottles but I won't really go into all that because it would take way to long. Haha
I started of by making my own Vacuum form buck using Garys profile of the original bottle, I made a 3D model of the exact shape and had it printed. I had original tried making the buck on a lathe and although I could get it close to accurate it just wasn't as close as I wanted.
Heres a few photo of my buck against a printout of Gary's tracing, you can just see the outline at the edge of the buck, I think its as spot on as you could ever get it!
Here I have offset it slightly to show the profiles side by side.
And here I drew around half of the profile in red pen to show how well it matches up.
This is the polished buck just before it got moulded.
I then moulded and cast two bucks ready for vacuum forming. I knew my master was the exact size that I wanted it to be so to avoid any shrinkage and also to help thermally when it came to vacuum forming I cast the bucks out with a mix of resin and aluminium powder.
It took me a looong as time to figure out the kinks when it came to getting good vacuum form pulls with good clarity but after buying a Ionized air gun the clarity in the pull was as good as I could possibly be for a vac form
I then trimmed the forms and then the hardest part of all came.
Gluing!!! I really have to give it to Gary Weaver. There is no easy way to make these bottle and have them screen accurate and gluing these things is not an easy task to figure out.
But I got there!
I also made some white pulls to make the Diet Pepsi bottle.
I then set out to make the flip up straw, I used exact measurements taken from emma's bottle. The rubber straw that runs through the middle of the bottle took me an extremely long time to find and get my hands on. It made it even harder that I am in the UK and the measurement of straw are in imperial so I had to order it from the US but I finally found the exact one.
The underside of the straw and how the ridge clear straw that rounds down the inside of the bottle where just as important to me to get right. There are not many photos of the underside for obvious reason that its hard to see. You can clearly see here how the original was constructed. Gary also posted photos of his production used bottle were you can see this much more clearly but I don't want to use his photo with out permission.
I quickly made up a prototype bottle with all the bits i have so far just to see how it looks and here it is. I haven't glued in the rigid straw that runs down the middle here so thats why its off to one side and obviously I still need to get Vinyl labels made etc. Sorry for the bad lighting.
Let me know what use think. I do plan on selling a few so if anyone is interested let me know. I will be posting more as I get further on with the project.
Downfall.
I have started and interest thread so please head over there to find out more, https://www.therpf.com/showthread.ph...69#post4394869
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