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Mould Prepping time!


To prepare the parts for moulding, I created a flange around all the edges using cardboard (and MDF for the gauntlets). I used hot glued to attach it.


I then created a fillet between the parts and the cardboard to remove any undercuts. For this I used plasticine that I warmed up on a radiator to keep it soft.  


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Prior to molding, I gave everything that was going to be made with a solid fiberglass mould several coats of release wax. I applied it generously with a sponge and buffed smooth with a soft cloth.  


[ATTACH=full]186534[/ATTACH]


Waxed and ready to mould...


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Thick layer of gel coat applied...


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Chopped strands of fibreglass to prevent air bubbles in the tight corners were added...


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Stippled down with resin...


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Two layers of chopped strand matting added...


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 More resin and making sure there are no air pockets...


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Left over night to cure and removed from the original.


The left gauntlet upper part, I had to mould slightly differently as there was an undercut I wouldn't have been able to get out of a solid mould...


[ATTACH=full]186543[/ATTACH]


A thin (beauty coat) layer of silicone was applied first and left to cure...


[ATTACH=full]186544[/ATTACH]


Then several thickened layers were applied (added thixotropic addative)...


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Locator keys were made with an ice cube tray and attached with more silicone...


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The silicone was left to cure over night and then two layers of fiberglass were applied to create a solid "jacket"...


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Once the fiberglass had set it could be removed from the original part.


For the small "greeblies" I made walls around them using hot glue and cardboard. I could then carefully pour in un-thickened silicone to create a simple silicone block mould.


[ATTACH=full]186549[/ATTACH]


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They were left over night to cure. The cardboard was then removed and the original parts were taken out. (forgot to take a pic! :()


[ATTACH=full]186553[/ATTACH]


Nice collection of moulds going on here... Time to cast some parts! :D


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