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Just a side project, but I took the A/C tube rubber rings that hold the clear rear deck vents and drew them up in SketchUp which is a free 3D modeling software.

Once done, I uploaded them to ShapeWays SharpWays to have them 3D printed in a strong/flexible black plastic, since rubber, silicone, or urethane was not an option. They also have other materials you can have things made in as well.

I didn't model the mounting holes, as I figure they then could be drilled to fit the application later.

I'll report back later to see if it was a successful endeavor, as I hope to use them to replace the petrified/cracker rubber ones that I have.

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that is an excellent idea, i think many things could be sent there for reproduction! i bought some stuff from that website before, but for my Nintendo 3DS. they can even print in different metals.

i believe it is shapeways though.

I've been playing around a little with those too but you beat me to it. Here is what I made out of two different UV stabilized Urethanes --65a and 80a shore hardness. These were cast from a mold taken off the one good but petrified rubber piece which fits the ducts I have. No idea if the ducts are the same size as yours though. Think mine are ARA.

It will be good to compare how the hard plastic works vs the more flexible urethane. If the mass production type works that would be great. If you want these PM me an address and I will send them when the cure time is complete and rough edges can be trimmed a bit more.

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Howard, yes! I would like to see how those fit and I really think they need some flex to them, and I am not sure how these "plastic" ones will do. It was just a test to see if it a possibility. I think yours are more faithful to the design.

I'm send you a PM.

I'm glad to see that both Kevin and Howard are getting all their ducts in a row!

I think the test will be sun and UV.

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Agreed. I have added UV stabilizers in the urethane pieces but time will be the test of how well they work. A color fading is one thing that can be painted over but cracking, turning to goo or otherwise falling apart is something else.

I don't know if anyone else has made parts of urethane that are in a hot area and exposed to the direct sun. Pieces I have made that are covered seem to be holding up very well so Kev may be the first test of the other extreme.

Anyone else have experience in this area or have anything made of cast urethane rubber?

Isn't that what they pretty much use for suspension parts now?