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Message from discussion Making Hard-shell molds
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Keith Franks  
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 More options Oct 13 2012, 10:04 pm
From: Keith Franks <keithdfra...@gmail.com>
Date: Sun, 14 Oct 2012 13:03:58 +1100
Local: Sat, Oct 13 2012 10:03 pm
Subject: Re: [CCHS] Re: Making Hard-shell molds
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Hey, I was looking into this a while back and found this link:

http://blog.makezine.com/2009/08/24/how-to-lost-foam-metal-casting/

Some more exploration around how this guy did things (you should be able to
find his website) shows some very cool hits and misses and great ideas for
different ways to do this...

Hope this helps.

On Sat, Oct 13, 2012 at 4:17 PM, John Spencer
<john.spencer.9...@gmail.com>wrote:

> I like the idea of using foam. I've heard of people routing it, but I'll
> have to do more research.

> With the hard coating is the mold reusable?

> John S

> On 13/10/2012, at 8:14 AM, samotage <sam.sa...@esskware.com.au> wrote:

> > What you should do is use polystyrene foam for the shaped mould, easy to
> carve etc.

> > Then use the 3M #77 spread adhesive (safe for polystyrene) to spray the
> surface and apply box tape (use heat gun on curves) to act as a release
> film.

> > After than, laminate with glass fibre!

> > Fill, sand, finish and paint.  The "mold" will either pop off, or can be
> dissolved out with acetone.

> > I've made many RC plane fuselages and moulds using these techniques, and
> its easy and fast.  Have a look on some of my threads on rcgroups.com for
> more info.

> > The only thing is an appreciation for sand papering :)

> > Sam, @samotage

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