Mold casting in polyester ?

pelleprognos · 2016-10-09T07:21:27+00:00

Hello. I can't find an appropriate forum to ask my question, so I'm trying here :) I want to make a copy of a profile in the shape of an airplane wing. It's about 55 cm long, 25 cm wide, 1-1.5 cm thick. It's slightly profiled and gently curved. The original profile has a core of some kind of foam and a thinner surface layer of something like reinforced polyester, hard and quite durable. My idea is to try to cast a copy in something like polyester. I was thinking of doing it like this. Use a box/mold that is slightly larger than the original profile. Place the original profile on spacers (about 4 cm) at the bottom of the mold. Pour in something like fine concrete, so that about 2/3 of the profile's thickness is covered. Let the concrete cure, dry. Detach the profile from the concrete. Place the profile back and cover with something like foil plastic. Fill up with about 5 cm of fine concrete, which then cures, dries. Then I should have a mold. Drill, shape filler holes, 3 pcs. In the lower half of the mold (has the largest imprint of the profile, 2/3 of the thickness), I pour a bit of polyester, lay fiberglass reinforcement, and continue layering as much as possible. Then place the upper part of the mold and fill up with just polyester in the filler holes. The problem might be that the polyester sticks in the mold, which will be difficult to separate? Will there be enough strength with maybe just a couple of layers of reinforcement, as the wing tips are quite thin and need to withstand some stress? Instead of using fine concrete for the mold, perhaps reinforced plaster is better. I'm a bit concerned about casting and damaging my original profile in the concrete. Feel free to share opinions, suggestions, etc.

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ToRy

#31

Member · Västra Götaland

· 3 575 posts

27 Oct 2016 at 3:21 PM

ToRy

Member

Västra Götaland
3,575 posts

27 Oct 2016 at 3:21 PM

Stylish! Out to try now then or!? :wow:

Mold casting in polyester ?

ToRy

ToRy

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