Advice for carving/sanding materials

Yarko

Well-Known Member
Hello!

I want to hear some opinions on this. I have an epoxy resin/fiberglass helmet I made a couple of years ago. I have decided that I want to fix some mistakes in the overall shape and also produce a smoother and sharper version. However, I find that dremel-ing, bondo-ing and sanding epoxy is a pain (specially because I have to do it outside and its really cold in here).

So I though I could make a casting in plaster, which would be way easier to work with. However I fear plaster might be too brittle and wouldn't allow me to get decent results.

Is there a third alternative you have used with success for such a thing? I've read about ultracal and hydrocal, but I don't think they are really 'carvable' or easy to tool.
 
Hydrocal is great for carving and shaping. It's a beta plaster, which means it's a little softer than the Ultracal but still very structurally sound.. It will take chisel, rasp, and file work like a treat.

I often had to retool lifecasts in hydrocal, to remove blemishes from the casts or even whole lips and eyelids. Super easy to get a nice machined surface.
 
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