Terminator T-800 Endo skull build

[Lunchbox]

Hello all,
This is my first build post so please be gentle. I recently picked up a "vinyl" T-800 skull kit for a winter project. Besides having the usual vinyl kit warping issues, it's a VERY POOR casting with thin spots, bubbles, and de-lamination. I guess my general goal is to get it into an acceptable shape, stiffen it up, and re-sculpt most of the details. Due to the poor quality of the "vinyl", i'm concerned that my plan of slush casting "rondo" or plain fiberglass resin into the skull will cause additional warping or just melt through. After the slushing, I'll be filling in the rest of the skull with 5 Lbs foam. Besides looking over past and present builds for tips and hints, I hope to gain knowledge from some of you experts so I don't botch this up. Pics should be coming soon.

 

[cavx]

I wouldn't use any polyester resins on this. They get hot, really hot as they kick. And they also stink for ages and if this is a "winter" project, then I guess all doors and windows are closed up.

I'd get a polyurethane like D65 to slush the inside. Whilst it heats up, it only reaches about 80 degrees C. It sets quick (usually 3 min) and has no residual smells.