solentlife
I have a spare HK Lanc set of plastic mouldings .... and I have finally plucked up the courage to cast plugs from them.

Here is first .... Tailgunners Turret.... 

[HK%20Lanc%20tail%20turret%202_zps8plritg7]

[HK%20Lanc%20tail%20turret%201_zpsxc7eisac]

Ply piece inserted so I have handle. Plastic is sprayed with silicon first to provide release.

Fingers crossed it doesn't lose me my spare mouldings !!  
I'll fly anything if I can launch it ! Youtube : solentlifeuk
Quote 1 0
solentlife
Once I have the hard plugs ....I will then attempt Pop Bottle forming with heat over them.
I'll fly anything if I can launch it ! Youtube : solentlifeuk
Quote 0 0
solentlife
[Cast%20tail%20turret_zpslyw24jsj]

It worked ..... but the plug really does not want to come out due to the air cannot get in behind, even with the pliable plastic.
I'll fly anything if I can launch it ! Youtube : solentlifeuk
Quote 1 0
solentlife
I think next test will be the damp sand way ....

Place original into damp sand to create female mould .... then carefully pour plaster into that.
I'll fly anything if I can launch it ! Youtube : solentlifeuk
Quote 2 0
bogusbandit56
I`ve always had a fascination with moulding. When I was at school I modeled a sports car that looked like a Ford GT40 in clay and then made a plaster cast and finally produced a fiber glass shell.
Wot, no Depron?
Quote 0 0
solentlife
Well the damp sand was not such a great idea. 
Damp sand is really OK only for surface detail items .... but deep such as cockpit canopy needs depth.

Will now look for casting 'Putty' ...... 

While looking - thought I would look at sandwich wrap as release medium .... 

Another idea of course is to create an exterior plaster cast ? 
I'll fly anything if I can launch it ! Youtube : solentlifeuk
Quote 1 0
solentlife
On we go .. 

I have found a better plaster that is grey in colour and much finer than the standard Gyps plaster. It sets 2x faster and has a very fine surface.

I am now experimenting with Baby Oil as a release agent .... 

Once I have all casts ... I will post piccies of them
I'll fly anything if I can launch it ! Youtube : solentlifeuk
Quote 0 0
solentlife
I tried the 'external' casting but it was really only good for very small item.

[DSCF8393_zpszvh6p3gn]

So I went back to pouring into the item to create plugs. The Baby Oil really made a difference instead of the silicon spray.

Here are :

Cockpit canopy Hk Lanc :

[DSCF8379_zpss1uy0p7v]

[DSCF8394_zpsfbmvrmdk]

Front gunner :

[DSCF8381_zpsvksqaed3]

[DSCF8395_zpsbbhkkkhx]

Upper turret and bomb aimer :

[DSCF8385_zpsgkgn5mod]

 [DSCF8386_zpsakgyakrp]

[DSCF8397_zpsi5ijuzp9]

Tail gunner :

[DSCF8384_zps0waexugg]

[DSCF8396_zpssznpnojj]

All with plywood holding sticks in ..... 

Now to learn how to hot form the plastic bottle over them !
I'll fly anything if I can launch it ! Youtube : solentlifeuk
Quote 2 0
Wildthing
Marvelous work 
Quote 0 0
solentlife
Thank you .... 

I am hoping that my bit of work here may inspire others to have a crack at it and I am sure can improve on my lowly attempts. If an amalgam of mine and others improvements can create a method using common 'household' products - that would be reward for me.

We all I think make mistake of breaking that moulded item BEFORE making a plug for any replacement needed. Given the ease of it ... there really should be no reason not to make that plug just in case.
I'll fly anything if I can launch it ! Youtube : solentlifeuk
Quote 1 0
solentlife
I have been asked about how to create a master item for casting .... TBH ... that is not something I am very good at ! But I attach some excellent pdf's from Wattflyer thread that ran some years ago ... 
I'll fly anything if I can launch it ! Youtube : solentlifeuk
Quote 1 0
Wildthing
Not having molds or should I say plugs  of anything an idea I just thought of and if you are good in 3D software you could create these plugs. You would have to probably coat or fiberglass it first to give you a smooth surface , this instead of  trimming , sanding a piece of wood or something like that to create the plug. 

Just a thought. 😉 
Quote 0 0
solentlife
Agree .. but I'm useless at 3D creation !

I am going to invest in a 3D scanner once workshop is up and running.
I'll fly anything if I can launch it ! Youtube : solentlifeuk
Quote 1 0