so the other ben, BEN A. started a thread over at joe customs, and did a really good job outlining some of the process so far, thought it was really cool. so take a look.
"Here are the shots of the molding process that I promised to show.
In this shot I am screwing plywood to the castle armature. Putting plywood on the back and bottom of the sculpt means that these areas will be open or accessible in the finished mold.
Here is the castle just before (I think) the first application of rubber.
The castle is now encased in a brushable urethane rubber. The rubber mold is about 1/4 inch thick. Each layer of the rubber has been dyed a different color to make sure the coats are even.
A close up.
With the rubber finished, we then begin the mother mold. Since the rubber is so thin, it requires a rigid shell to help keep its shape during casting, called a mother mold. We determined we would need a 5 piece shell for the mold to release from the cast properly, due to all the undercuts in our model. The point where each of the 5 pieces meet is called a parting line or shim line. This photo shows the beginning of the "shimming" process. Cardboard walls are used to divide the model into 5 sections. The marbles will become registration keys so that the mother mold will fit back together properly.
Here we have applied fiberglass mat and boat resin to the model, creating the first 3 sections of the mother mold.
This is the 4th and largest section of the mother mold.
With all 5 sections completed, we begin trimming the fiberglass shell.
Here I am removing the fiberglass shell from the model. It tends to cling pretty tightly to the rubber when removing it for the first time. It actually turned out to be quite an ordeal. If I were to do it over again, I might use a 7 or 8 piece mother mold.
This is me holding up the fiberglass shell, winded but triumphant!
Last edited by bishart; May 30, 2011 at 12:51pm.
continued.... from BEN A.
Pics of the finished mold. The urethane rubber picked up a lot of the clay from our sculpt, hence the residue on the inside of the mold. That all had to be cleaned out prior to casting. A silicone rubber mold would not have done that.
The first casting attempt.
A release agent was applied and the plastic was sprayed into the mold using the gun thats laying on the ground.
It turned out to be too flimsy a material to hold its shape. We are trying out another method as we speak, so no pics of the cast just yet. The next photos we post will hopefully be a fully outfitted, painted cast."
i hope you get everything worked out. best of luck on this project. it looks awesome.
you can see pics of all my projects on my facebook page. facebook.com/don.schomer or email me :firstname.lastname@example.org
that is amazing!!!!!!!!!.................................. .................................................. ..................
This is really cool... Thanks for sharing the processes with us!
Over ELEVENTHOUSAND views of this thread!??!!
Now talk about popularity!
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This whole thing is amazing.
check out my artwork at geooco.blogspot.com
Soooo...enquiring minds want to know....are there any plans for floor peices that we can insert to make a throne room, dungeon etc in the works? Or maybe a throne and weapon trainer like the original greyskull? Sort of like an evil Ikea package that can be installed later. That thing so needs to have an interior
Posing my figures doesn't mean I'm playing with them!
my fortress will be up against a wall, with guys all over it, haha there will be no moving this 3 ft monster.
I want to see more please
Only one of anybody.
I come back top look at this thread all the time because it is just STUNNING! The level of talent and ingenuity here is incredibly impressive and I just can't get enough of seeing it progress. I bet when that first successful cast comes out as one solid piece that it's going to be mind-blowing! Thanks a million for your time, effort, and forethought to DOCUMENT the whole process so we could see everything that's going into it.
The wait for final pictures is all worth it.
I too have visited this thread many times, thanks for letting us share in your epic journey and I await the journey's end with great anticipation!!
DT81's Tinkering thread - http://www.he-man.org/forums/boards/...nkering-thread
Check out all my customs over at figure realm
WOW this is awsome!
why not try to do it with the foam?
per il potere di grayskull! a me il potere!
one word to describe it: nerdgasmic. are there plans to make multiples with this mold you are making to sell to he-maniacs?
thats truley a work of art. great efforts im impressed to say the least. i love the accuracy of both realness and cannon likeness. great work.
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That's unreal. Total art