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Aluminum Epoxy Molds


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Gentlemen and Ladies,

 

I thought some of you might be interested in my latest endeavor.

 

Well, it seems this last year's rapid rise in requests for suits and gear has taken it's toll on my Hydrocal molds. Poor things never stood a chance with these kinds of heat cycles. Previously, if and when a mold chipped or cracked I could fab a replacement 'toot-sweet' and 'on the cheap' but there comes a point when One must recognize a need for change. So, I have been busy recasting all my molds in Aluminum Epoxy. This will accomplish several things:

 

-The molds will better tolerate repeated heat cycles.

-Will be less suseptible to chipping. Will keep sharper detail.

-Will be a fair bit lighter and can be repaired somewhat more easily.

-Machinable and sandable are always good options as well.

 

 

rWXXJpy.jpg

 

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The numbers written on the molds represent the number of litres/quarts required to fill the void.

 

haU99xi.jpg

 

 

 

The cost of this stuff would make having solid molds cost prohibitive so I opted to go for a foam core wilth a 3/8 shell of Alum/Epoxy around it.

 

First I molded my old molds. Then filled them with expandable foam. Then shaved of the 3/8". Then filled the molds with the Alum/Epoxy, insrerted the foam and let it set. Removed the part, cleaned up the edges and surfaces and, voila, new molds.

 

It has been a bit time consuming, has delayed some folks gear and I'm not finished them all yet but I think the end product will be improved.

 

Some day I will get around to completing my interior kit. I promise :)

 

Cheers,

 

Rob

 

GCJ6rPG.jpg

This is what happens when your kids get a hold of your phone..

 

Edited by gmrhodes13
photo updated gmrhodes13 2021
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Uh....did rob just recast himself?....lol

I just laughed in an out loud manner.... For reals.

 

-Eric

 

 

 

 

Sent from my iPhone using Tapatalk

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