Aluminum body Bronco Build along~

[LoneRanger]

First off, special thanks to Metal Masher for doing it first. Second thanks for fielding many PM's over the last year or 2? Your help on the phone came in handy- as anything goes I have made a few adjustments and since your up at the comp I can exactly "call" you and say hey man I did "this". I have had the stuff to make the molds for over a year now. I also have every Bronco body made (and multiples) from every manufacturer- (except the Dynamic Concepts wraith body)

I chose to go with the Proline body as it is a fairly large body as the bronco goes, and it will make an easier class 1 truck using commonly available axles (scx10 width) The largest problem with the proline body is it is too damn long. (by better than a half inch) Doing the molds will allow me to make it the "correct" size and proportions for a real bronco.

Most of the pics here are stuff Metal Masher has already posted in many of his build threads- I am going to try to do a quick video of the mixing of the resin, the pour, and watching it kick off.

like all of my build type threads don't expect this to happen over night.

PICS:
this is smooth cast 300, a casting resin. there are 2 dark blue cups one on the right and one on the left- part A and part B. I take each and fill to desired levels in those cups and dump them together into the white cup in the center the cup my broken arrow shaft/ mixing stick is simply for holding the mixing stick after I am done mixing. the cup off to the left had water in it. The first side I did I folded up a towel to support the body after making a dam in it to hold the resin in place. a light dusting inside the body with some baby powder works like a release agent letting the resin "pop" out (most of the time) When the resin was mixed I poured it into the dam I made with tooling foil and painters tape. as it started to kick off I took the wate rcup and poured it over the body and into the towel supporting that side. the water wicked through the towel and kept the body cool. (the resin gets to around 200* which is hot enough to distort the lexan if not cooled.


damned up~


at the right angle to get everything I need evenly covered.


tape removed on the front fender tooling foil left in place.


foil removed~


rear form pulled-


drivers side popped- I had to make a tool to help release the body so I used some .060 styrene and beveled the narrow edge, slid between the lexan and the resin and it popped right off then.


The next side I tried something different and instead of using the towel I filled the sink with water and right after I poured the resin in I set the whole thing down in the sink. nothing dissipates heat better than water!!!


tada 2 sides!


so here is a little better on how I make the dams. clean body, small strip of tooling foil and painters tape~


strip of tape across foil~


tape it up just below the bumper mold line-


outside in-


add tape to dam it all in-


pour in resin and set it in the water~


set up~


pulling tape~


peel foil away~


tada!


THE END RESULT-


Will shoot to do a 3 or 4 min video of the hood when I do that one. (or the roof?)

thanks~

L.R.

[Nvghostrider]

Subscribed!

[AkFordfan]

Dang you, now I'm going to have to do this

[LoneRanger]

I'll send you the castings when I am done, and you can send me a set of long arms for the trail rig. Duffs or Cage would be fine. Mighty fine trade if ya ask me!

L.R.

[vipxj]

Watching this build for sure,

[LoneRanger]

ok, I have made 2 videos- mixing and pouring as well as popping. my internet sucks so bear with me, it will probably be tonight before they are posted.

L.R.

[LoneRanger]

Video 1- how to "make a cast part"
Making a mold - YouTube

L.R.

[BigSki]

You could use a release agent on the lexan so the resin will just slide off.

[AkFordfan]

Ide rather have tamiya molds , and if I buy arms their going on mine

[LoneRanger]

I did use a release agent. It is called Baby Powder. I mentioned that in my post above.
Part 2 popping the mold-
Popping the roof out! - YouTube

L.R.

[cmbscx10]

Wow! Nice job so far. Definitely subscribed. I wish i could do this but my ADD kicks in too much. Looking forward to the final result. Will be awesome. I haven't seen scale Dzus fasteners but that would be a cool addition for some of the panels.

[LoneRanger]

my ADD isnt liking this project! I would love to have this body done before the G6 comes to town in October. We'll see. I have questions for Metal Masher and I know he has the answers too them! I just popped the hood this am- as of right now I have ALL of the forms to make my panels. I have formed the tailgate which came out smokin, and I have done the rear lift gate. The fenders are QUITE a DIFFERENT STORY! the bends are so extreme around the fender flares its tough to get them right. fun project none the less. and moonshine makes any project more fun! haha

L.R.

[Metal Masher]

Looks great so far! Good job on the write-up. i was planning on doing one myself but just never found time.

[LoneRanger]

so here I have one half of the truck cut into pieces to do the metal forming-


now everything is laid out-


tailgate came out great!


more parts (first fender attempt)


hood was the final piece to do~


lift gate progress


i used tape to hold the foil tight on the sides then went to beding and forming the foil.


little further along-


finished piece- along with some tools I "made" to help with the forming.



and a full set of completed panels. the hood, grille, and tailgate need to be narrowed up for this truck.


L.R.

[Kel]

WOW! Brilliant idea... Subscribed

[MountainStorm]

What type of metal and what gauge? Love the process. Looks great.

[Alpha Male]

I've seen a few pictures of the metal Toyota body before but never in person. Don't they crumple during your first roll over? Do you leave the mold inside to support the metal?

Sorry, I'm not that bright.

[LoneRanger]

The goal is FOR them to crumple! it's the ultimate scale body. Every dent, crease, and scratch shows up in the body just like a 1:1.
The panels are surprisingly ridged once they are made over the forms. Should you desire a stiffer panel, just lie a strip or 2 of the aluminum to the back side of the panel and glue them together.

L.R.

[R/CMaxximus5.0]

Nice work! I admire the dedication to a build like this, subscribed.

[Maddog Madigan]

What thickness of foil is being used, thanks for sharing.