Cast/Mold Sandtrooper Backpack..Help?

[kelsobrooks]

Hi;

I am working on making my own Sandtrooper Backpack for my cousins trooper costume.

I have used clay to make a "mold" of the Radio part using various knobs and circles, etc.... My question is what product do I use to make the actual "cast". I have heard people say use Smooth-On, but when I go to the webpage there are like 20 different product etc....

Any guidance or suggestion to what I should purchase would be appreciated. Also I have no idea of how much to purchase of the required amount. I am hoping to make about a 1 inch thick radio front that I will attach to something else to make the whole box radio part. See radio looking thing in image below:

NOTE: I may be using the terms Cast and Mold incorrectly....?:$

Thanks for any help you guys rock!


Kelso

 

[exoray]

Call them an inquire about a 'sample' or 'starter' molding and casting kit...

FYI you are not going to want to cat that entire front piece 1" thick, look up slush casting or consider doing a fiberglass layup instead...

 

[KaanE]

The clay you've used is sulfure free? Some silicones won't "dry" correctly with clays with sulfures...

I haven't used any Smooth-On products but what people uses over the 405th is Rebound® 25 Self Thickening Brush-On Silicone Rubber (Rebound® 25 Brush-On Silicone Product Information | Smooth-On) for the mould with a fiberglass jacket, and then, for the cast, they use Smooth-Cast® 300 Series Bright White Liquid Plastic (Smooth-Cast® 300, 300Q, 305, 310 Product Information | Smooth-On) or simply use fiberglas reinforced polyester resin.

But your best bet is buying a Starter set which contains Brush-On Silicone for the mould and also Smooth-Cast 300 for the cast. (Brush-On Silicone Starter Kit: Rebound® 25 & Smooth-Cast® 300).

 

[kelsobrooks]

Thanks for the information so far....

Kaane, If I have used Non-sulfur clay, I can just use the "Rebound 25" by mixing then pouring into my mold...? Then I will end up with a Rubber Cast front of the radio... Is that Correct?


Thansk again..

Kelso

 

[KaanE]

What you have is the master (the clay radio). With the Rebound 25 you will do the mould of this clay master aplying a few coats of Rebound with a brush. Then, when the mould is done you need to do a support so the silicone keep its shape. This is usually made with fiberglass (cheapest and fastest way). Now you have the mould done.

Now onto the cast. I've never worked with Smooth-Cast but it's easy. Just mix the two compounds and pour it into the mould. Keep moving the mould so the resin gets an homogeneous thickness all over the mould until it's dry (around 5 minutes). And then you'll have a cast of your clay master.

Anyway, the Starter kit comes with a How-To DVD and you can also find tutorials all over the Smooth-On here:

Mold Making Videos and Photo Tutorials presented by Smooth-On, Inc

 

[Phelyx]

That's a pretty big piece. I'd consider making the big boxy part out of sheet PVC, and then just cast the face part with the details as a flat piece - or as several detail pieces - to stick on the box. Resin can get expensive, and it's best for detailed shapes. When you're making larger, square shapes, sometimes it's better to build those basic shapes with styrene or wood.

 

[Superkrates]

Here ya go:

How To Build A Stormtrooper Costume

9th one down is the How to build a Sandtrooper Backpack. Enjoy.

 

[Etewaf]

Making a One Piece Urethane Block Mold

Check this video out, I think it'll give you the basic idea.