I'm back with a Sub-Malevolent update.
After some quality research online, I gave the matrix mold process a try. I have a fair amount of experience with mold making, but am no master. This is my first time working with fiberglass so I made sure to know what was going down before I dove in. Thankfully there is a fair amount of tutorial material on Youtube regarding fiberglass technique, albeit mostly geared towards automotive and aquatic body work. The work of Volpin Props and Punished Props also gave a lot of insight into the process, though you don't really know until you actually do it. As with most skills it is all about miles, research, and proper preparation. I'm not going to go through the details of the process, as it is just mostly busy work.
Here is a photo of the main body after the first application of silicone. Lots of clamping going on in that photo. I like the DeWalt clamps, they remind me of Hyperion.
After some deliberation about process, I hand roto-cast the first copy in Smooth-on, Smooth cast 305. This was quite difficult as the mold, jacket, and resin together weigh in around 35 lbs. My arms got quite the workout. I'll be building a rotocast machine to help with this process over the next couple weeks. Until then I'll just make sure to eat my Wheaties.
Here is the first cast of both the foregrip and the main body, freshly cured, next to the original sculpt. I am extremely pleased with the results. It looks as though my details were captured quite well.
I am on hold until more resin is acquired so my next move is to paint and fully detail my original sculpt...
As well as mold the Flakker....
And finish the Bandit Shotty....
Awesome.