08 August 2008:
After a looong hiatus, I continued working with manufacturing the bosses for door handles.
10 August
2008:
I manufactured
and glued the chrome trim frames at the rear.
I
manufactured and glued the rear vent
grilles.
12 August
2008:
I applied a primer
coat. Needs some more putty+sanding..
16 August
2008:
I prepared the
RTV silicon mold setup. I glued a peripheral skirt under the body so
that
all the body would be submerged in the silicon but the silicon would
not
enter the inside.
Then
I poured the silicon in the mold.
The body floated (well, naturally..) and so I put some iron weights to
keep it submerged.
17 August
2008:
After the silicon
cured, I took off the master model and laid resin, reinforced with
tissue
paper at all sides.
Ta-daaa!!
I took off the first resin
sample from the mold. I will shave off the flashes, apply a primer and
see if there is anything wrong.
31 August
2008:
The first sample
was full of cavities, so during the past couple of days I prepared a
new
female mold, taking more care this time. I laid resin surface by
surface
again, this time got a model with good surface. I will use this model
as
the gap setter between the female and male molds.
To prevent closing
of the gap due to sagging of the male mold while casting, I prepared 2
copper inserts for the male mols to act as a skeleton. I drilled holes
here and there, to facilitate the spreading of silicone while pouring,
and to act as gripping elements between the silicone and the metal when
cured.
To
provide some means for exact positioning
of the male mold, I bent the edges of the copper sheets to form a
resting
surface on the female mold.To prevent distortion while pouring
silicone,
I put some iron weights on the copper surfaces. I made a filling runner
from the body of a plastic injector and fixed it inside the roof. Now
the
setup is ready for silicon pouring.
I
poured silicone to form the male
mold. I hope all end up alright...
01 September
2008:
Unfortunately
the male mold did not easily come out of the body and the body was
broken
while stretching. I will try a multi-piece male mold.
05 September
2008:
To produce a
flexible body, I applied a shell of plastic with a glue gun.
And
I got a flexible body shell to
make the 2-piece male mold.
06 September
2008:
To smoothen the
traces of the glue gun on the inside, I covered all the inside with
masking
tape. I poured the slicone for the first part. I put a non-drying
molding
paste inside, with a slant so that the two pieces could be taken apart
easily. After it cured, I covered the whole surface with Humbrol Maskol
so that the second poured silicone would not stick to the first one.
Then
I poured the silicone in the second part.
08 September
2008:
I used acrylic
polyester resin and BINGO! The part was very acceptable.. The black
rectangles
embedded in the body are styrene spacers that I put between the male
and
female molds to prevent touching.
29 March 2009:
The top contours
of the windshield was incorrect, so I corrected the master model and
made
a new female silicone mold. I made a new body and cut out the windows,
wheelarches etc. I also prepared a mold for the floor and got a sample
casting, but I have to work on it more.
03 April 2009:
I made silicone
molds for the front chassis arms and cast resin parts.
I
joined the parts with CA glue and
applied primer paint.
...................
......................
