View new posts | View your posts Pics of my pack mold (Update: 1/2/07 w/ a question)...

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Hey guys,

I posted my fiberglass shell progress on Proptopia but wanted to post here too if no one minds. Any input would be great.

Wood pack ready for molding (before I redid the NFilter to make it more accurate):


Poured the rebound-25 over the master:


Plasti-paste support shell (later I made a bondo support shell from Sean's plans):
http://www.fileden.com/files/2007/1/8/6 ... C01728.JPG

Silicone mold:


More Silicone:


Fiberglass Shell:








Inside of shell:


Can't thank Sean and AJ quick enough...

how much would you sell one for?

PM me....

Nice shell man.

Thanks! Appreciate it.

I was starting to doubt my skills a bit after seeing these styrene packs. I like the rough look though...

Forgot about this thread I posted and noticed I hadn't posted many pics of the construction processes.













^^ I eventually used a pringles can instead of the pipe.





^^ Some guns I made for my kids.

Man that process was fun. Love working with MDF.

Looks great!

looks great!

That's pretty sweet looking so far.

Thanks guys.

It's actually already completed. I was just going thru older photos and decided to post them on this thread.

I'm working on version 1.5 of the pack which is making the curve between the power cell, and replacing the power cell and gear box fins with 1/8" wood as opposed to the 1/4" that I used.

The current state of the wood pack that I will remold next week. It's been thru hell and back as you might tell.















^ ^ Regarding the last pic, I actually added the curve between the power cell as it didn't have one before. I was wondering if the curve is a difference between the GB1 and GB2 packs at all? Just wondering as I know some builders don't add it.

Can't wait to get this remolded though.

Lookin' good, man. Can't wait to see the mold.

-Todd

Update:

Wood pack with some misc parts on it including wand mock-up before doing a bunch of sanding and primering:



Likewise:





After that I actually rebuilt a few parts including the corner plate and power cell, etc...

Ready to be molded:







First coat of silicone... didn't mix the blue dye all the way but it looks cool multi colored I think:





Fourth and last coat:



Clay bisecting fin:



Support shell:



Glassed up:



Should be pulling the shell tomorrow after more than a week of working on it....

And here's a video of the wand mock-up. Gotta finish a few parts including gun track, knobs/buttons etc.

http://www.youtube.com/watch?v=O25WePXnniU

Shockwave,
Where did you buy the silicone material from and what is the name of it? I'll be making a mold myself in the up coming months and haven't been able to locate the silicone material yet.

Rebound 25 with blue dye/pigment from smooth-on but I got it from Wasco on account of they have faster shipping...

Your pack looks great by the way. Your pictures show alot of detail and how to do it aswell which will help me out for sure. I assume you purchased the gallon size?

Right, the gallon kit. And thanks for the compliment.

That is one sweet looking mold. More detail than I've seen on any other basic shell.
Great work; really impressive.

Thanks man. Just demolded the wood pack from the support shell and that was a real b*tch due to the booster.

I can see how that would be a pain. Still , IMO, it helps make the shell. You just don't see a lot of molded shells with the booster as part of the mold.
Also, that wand is BADASS. You are skilled, sir. (Hats Off)

Ha! The silicone looks like slime with the bad dye mix. I was going to say that pack looked HEAVY, but if you are doing a cast, you want something solid. Looks good so far. Is that a resin Clippard? Are you doing 100% casting, or will you cut out smaller pieces and replace them for more realism? Just wondering...

Yeah the resin parts on the photo I got from Propfan. I was gonna scratch build those parts (except the clippard of course) but decided to just go to him as I want to finally move on to different props, ie, trap, PKE, etc...

Whenever I'm working with that orange silicone I also think that it looks like slime. More pics to come tonight.

It does look like it got slimed by a blue Class-5. Still a great mold, tho.

New pics!!:

Bumper and booster frame courtesy of PropFan. Gonna re-do the PPD. One thing is missing which is the gun that I'm hoping to get finished next week.







Just for fun I chromed up the mock up wand (building the new one right now):

Nice pull from the mold, dude. Looking forward to seeing the re-done Nutrona Wand. I thought the first one was pretty damn cool; I'm sure the new one will look even better.

-Todd

I had a question regarding 2 part molds and the pack.

Since I'm not very fond of the fiberglass process, I was wondering if (later on) I can make a 2 part silicone mold from my fiberglass shell. That way I can pour casting resin in the 2 part mold and not have to glass it...

Would that be possible?

just found these pics great post and i will go off these for detail thanks jimmy

Google "slush casting"

But, for something as large as the pack you will experience a pretty brittle slush casting that will be prone to shattering if a blunt force hit it...

Fiberglass is the best option, and honestly IMO the only way to do it...

Thanks for the info.

I think I saw a slush casted pack on ebay a couple times. Looked weird on the inside and I wondered how sturdy it was.

BTW, I'm ready to order one of your new light/sound kits.

Hey. Haven't been on the board in forever, but i saw this and just wanted to say shockwave does a really good shell. I got one from him around november and it was really cool...little bondo and all the wires and tubes and it will look awesome...i took a break for the holidays, and i need to get some more stuff but when i start working on it again i'll put up some pics...so yea..shockwave good job man.