I've been reading through the past posts, but have not found a discussion dealing with this.
I need to make replicas for a training program, but they need to have approximately the same weight as the metal originals. I can't say what they are replicas of, but if you picture a common handgun you will be close enough (handheld tool, made of metal, partly hollow).
These replica tools need to be rigid and able to withstand being dropped on the floor occasionally.
So our thought was to do the following:
1) make a silicone mold of the tool
2) do a slush or rotational cast using some rigid urethane
3) drill a hole in the end and pour in enough lead or steel shot to reach the correct weight
4) caulk the hole closed
I would really appreciate hearing your thoughts before we jump into this.
Is it a bad idea? Is there a better way? Any suggestions on a casting resin that is rigid but not too brittle? What rigid resins slush cast well?
Is it perhaps possible to mix metal shot with a resin and just do a solid pour? This would be great for simplicity, but I picture all the shot sinking to the bottom of the pour.
I really appreciate your help. It was great to find such a talented bunch willing to help with other people's projects. Thanks!