I am not an expert, neither on recasting nor on other legal issues

But in my opinion, it depends on the final product.
To give you an example what I mean, let's pick something that often pops up here, a Daft Punk helmet:
Scenario A: I start from scratch, use my own design (which, of course, is based on the original), mold it, cast it, sell the copies - that's definitely no recasting.
Scenario B: I buy a casting, make a mold of it and sell the castings - that's definitely recasting.
Scenario C: I get a Pepakura-file of the helmet, print it, glue it together and go all crazy on it with resin and bondo and so on, then make a mold of it and sell the castings, I'd still be using someone's work (namely the file) to start my work, but I put a lot of effort and craftmanship in it to make it
my project at the end. Recasting? Not in my opinion.
Scenario D: I buy a casting, like in scenario B, but this time, I make...idk, a crossover-helmet to make it look like a viking helmet, with horns and rivets and all kind of additional work. When finished, I make a casting of this "new" helmet, making it very distinguashable from the original. Recasting? Dunno, but in my opinion, that is some kind of grey area.
And depending on the final product, the guy could be in this grey area. It depends (as said, in my opinion) on what the original and on what his final product will look like. Are they distinguishable, is his product really something "new"? Is his method just a shortcut to save him some work in the beginning, but he goes crazy on the details so it really comes out as something never seen before? Or does it look like an old candle with a new wick when he is finished?
There might be others here with other opinions, but in my opinion, at this stage, there cannot be a definite answer to whether or not it is recasting.
Oh, and btw, I'm actually not reading something about him selling the copies (although I gotta say I didn't read the whole thread). And as long as he's not making money with it, he can do whatever the heck you want
