Composite parts made easy

[Mike Poulson]

Here is a fun project.

Using pink foam and gypsum casting plaster you can make a wide varity of parts.

I searched the local phone book and found casting plaster at an art supply store. 90lbs. $30.00. You should get 2 5gallon containers to keep it in. It comes in a bag like cement and can be messy without the plastic containers.

You can get Pink foam from Home Depot, pink is the harder stuff most blue foam is soft.

A small hot wire tool is very usefull.

So you will be out about 50.00 and have enough stuff to last years.


MikeP

[Mike Poulson]

Make the part you want out of foam.

[Mike Poulson]

Slice up some foam for a box to make a mold in. I use 3M77 spray glue to assemble everthing.

[Mike Poulson]

Fillerup with plaster, pounding the table will release any air pockets as you fill the box. This one took 3 batches to fill. Try to make the top flat as that will be the bottom of the mold.

[Mike Poulson]

While the plaster is still "green" is a good time to clean it up. I use a good wood chisel to clean the edges and well used 80 grit to smooth out the foam texture left in the finish.

The mold needs to dry out for a couple days before continuing.

[Mike Poulson]

The mold needs to be sealed with epoxy, you can spend as much time as you want to get that perfect finish in the mold.

[Mike Poulson]

Wax the mold and lay it up.

[Mike Poulson]

Some shots of the finished part with just a litte triming left for final fit.

[JohnRobHolmes]

What kind of wax do you use?

[Mike Poulson]

Now, I really want a red rig. So I mixed up some epoxy, added red automotive paint and used it for a gel coat. That way any deep rock rash will not remove color as it will be solid red.

[Robb]

Originally Posted by johnrobholmes

What kind of wax do you use?

Ha, that was my same question, and the only part of the write-up that I didn't quite understand.

Besides that little detail, EXCELLENT write-up Mike!!!!

[Mike Poulson]

Here are some pics of supplies I use.

Partall mold release wax
West systems products
Brushes and alcohol to clean brushes

[Mike Poulson]

A shot of the home made oven. Its made from foil coverd insulation, 2 light bulbs a light dimmer switch and a digital thermometer. At WOT it will do 160 deg.
I will be able to pull the new red parts later tonight instead of tomorrow. About a 1/2 hour at 80 deg. until its good and firm then 100-120 for a couple hours.

[Cole82]

Great how to Mike

I have used old fashioned turtle wax in a pinch. It does work, just not as smooth as real mold release.
Also Chalk is another good option for coloring your epoxy. I buy the clored chalk for chalk lines.

[gone_wheelin]

That is cool. I might have to hit up the local TAP Plastics to see what I can find.

Mike - Can you post up some pics of the red parts you made? I'm curious how those came out.

[Mike Poulson]

Will have some pic's soon. I will do a build thread on this new rig.
Due to the untimely death of my best friend and long time RC buddy, my motivation is low.

Mike

[Unholy]

My condolences on your buddy.


Just get back on the hobby wagon, as I am sure your friend would have wanted you to. Build it as a tribute!

[SMR4RUNNER]

Gotta follow this thread.

Great work Mike.

[Mike Poulson]

Howdy,

Here are the red parts.

[stumpjumper21]

how do u get the carbon fiber to hold the shape of the mold?

sorry im a newbie