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HDD Mod Trials, Update 3:
Fabrication methods (and some trial materials)
 
Success Grading System:
{successful}         [Semi-successful]         (unsuccessful)
Based on new methods of production, the time taken, and overall the look achieved.
Distortion or scratches in plastic that can be avoided in future production may be overlooked.
ie) HDD 4 grades as successful though the plastic has air bubbles, which can be avoided in future production via better equipment (industrial) and finer temperature monitoring.
ie) HDD 5 grades as semi-successful though the plastic has an exaggerated frosted appearance and some platic smudges, both are effects of mold hardeners used on the molds which won't be used again.
ie) HDD 6 grades as successful though the plastic has air bubbles (used Method-D7 RE: HDD4). The mold may be attempted several times due to the extreme depth of the lid which can cause distortions in the XXXXXXXXXXXX upon vacuum forming.

Older Seagate with epoxied window.   (unsuccessful)
-Epoxy (PC11) doesn't adhere to XXXXXXXXXXXX very well and takes too long to dry, UV will break down epoxies.
1A1B
1C1D

Older Seagate with bolted on window.   [Semi-successful]
-Pretty fast to make and looks bullet proof. (very tough! :D )
2A2B
2C2D

Very old Seagate with multi-layer cutout lid.   (unsuccessful)
-Takes too long to make and doesn't look professional.
3A3B
3C3D

Western Digital with vacuum-formed lid.   {successful}
-Quick to make, looks real good, but will have some tiny trapped air bubbles.
4A4B
4C4D
As you can see above, the lid is much thicker than the original stamped steel lid.
Thinner plastic sheets can cure that to some extent.
 

Older Seagate with vacuum-formed lid and silicon seal.   [Semi-successful]
-Quick to make, the silicon seal hurts the look, still has a few very small air bubbles.
5A5B
5C5D
Tried new method of applying the silicon seal (in a string-like manner), but it still looks less than desireable.
NOTE: - You can really see the slight frosted appearance the plastic picks up from vacuum forming (and mold).
- This effect was furthered by the mold harder(s) that I tried.
- Most mold harders will mark the plastic in other ways (Pic 5B, top right of lid has 2 large smudges).
 

late 90's Seagate with vacuum-formed lid and Aluminum seal-tape.   {successful}
-Harder to make mold, Quick to assemble, looks great!, still has a few very small air bubbles.
-The mold may be attempted several times due to the extreme depth of the lid.
-Tape is expensive and must be custom order from XXXXXXXXXXXXX, bulk purchase only.
-Used method D7 with release agent XXXXXXXXXXXXX and mold type XXXXXXXXXXXXX.
6A6B
6C6D


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