So, some time ago (years), I got this idea in my head. It all started with research for a much desired project. That project has almost come to fruition (taking longer than expected, again sorry to all those involved). The research, with a little bit more work, lends itself well to a MUCH larger project.
I am now working up the new larger plans needed. Still a fair bit of engineering to do, and source some hard to fins parts, and things... It is looking more and more viable. But... To make it really doable (and maybe repeatable), many elements will need to be mastered, molded, and cast.
The parts I am looking at duplicating are bigger than your average model parts (even for studio scale stuff). The three parts that I have so far that will need casting measure out as follows: 1) 38" roundish x 38", hollow, with inner and outer detail. 2) 30" disk x 15" that fits into part #1. And 3) 30" disk x 4". Part #1 is smooth inner and outer (but with one undercut), parts #2 & #3 are one sided, but contain many thinner fins and rings that stick out from the surface. They are not supper thin (3/4" x 2 1/4" deep), so getting material into them will not be an issue (I think).
To do these, the idea is to make a master out of whatever works, make a set of fiberglass molds, and then cast them in fiberglass in those molds. While I understand the principle in this method, I have not made BIG molds or parts like this before. Mold release becomes VERY important in this, I know that. Usually a wax based product.
For part #1, I was thinking of two molds/parts that are then joined together in a jig. They can either be, for the final product, set up over a wooden frame for the, or filled up expanding foam. The jig would hold the parts stiff, so the foam would not distort the part. I guess parts #2 & #3 could be back filled with foam as well to make them strong and less susceptible to damage.
Thoughts?? Ideas?? Advice?? Links to more info??
Thanks in advance guys.
Thanks for the link Rog.
