RT-Mod Rob[501st] Posted June 7, 2013 Report Share Posted June 7, 2013 (edited) 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. The numbers written on the molds represent the number of litres/quarts required to fill the void. 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 This is what happens when your kids get a hold of your phone.. Edited January 18, 2021 by gmrhodes13 photo updated gmrhodes13 2021 Quote Link to comment Share on other sites More sharing options...
TK bondservnt[501st] Posted June 7, 2013 Report Share Posted June 7, 2013 looks like you're on the right track on every level rob! love it@! Quote Link to comment Share on other sites More sharing options...
TrooperJesse[TK] Posted June 11, 2013 Report Share Posted June 11, 2013 Man that is great! That means more armor making... Hopefully those molds will last you much longer time then the ones you previously had. Does that mean the cost will slightly go up? Or will it still be the same Rob? Quote Link to comment Share on other sites More sharing options...
walt[501st] Posted June 11, 2013 Report Share Posted June 11, 2013 Uh....did rob just recast himself?....lol Quote Link to comment Share on other sites More sharing options...
Darth Aloha[Admin] Posted June 12, 2013 Report Share Posted June 12, 2013 Uh....did rob just recast himself?....lol I just laughed in an out loud manner.... For reals. -Eric Sent from my iPhone using Tapatalk Quote Link to comment Share on other sites More sharing options...
Scootch[TK] Posted June 12, 2013 Report Share Posted June 12, 2013 You will love it, I have replaced several of mine with resin also. Quote Link to comment Share on other sites More sharing options...
walt[501st] Posted June 14, 2013 Report Share Posted June 14, 2013 I am using the epoxy cast from smooth on,,,,,,,,,whats the thought on that product? Quote Link to comment Share on other sites More sharing options...
RT-Mod Rob[501st] Posted June 16, 2013 Author Report Share Posted June 16, 2013 I'm finding the Smooth-On product pretty straight forward. I've been mixing the full package be it the gallon or pints and using a non-aerating drill mixer. It pours nicely into the molds and picks up all the detail. Sands beautifully. Quote Link to comment Share on other sites More sharing options...
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