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RENAULT 12

REPLICA OF THE RALLY CAR IN 1977 LONDON-SYDNEY RALLY, TEAM TURKEY.
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Started: 29 October 2005
Finished: 03 May 2009

Page 5 of 9

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.