I will have this project completed by October 26 2008.
I am going to assume that if you are considering this project that you have consulted the following book:
The Prop Builder's Molding & Casting Handbook
by Thurston James.
If you haven't at least looked @ this book -
DO NOT ATTMPT THIS PROJECT
You will make expensive mistakes & frustrate yourself.
If you have questions regarding the steps or ideas used to produce this project :
Feel free to ask - I only ask that you post them as comments because i may not reply to e-mails & I will most certainly post answers.
Step 1: Initial cast from mold...
I am assuming that you have an item or have created an item to copy.
As you can see - the detail is present but there will be alot of aesthetic work to be done.
Bondo is a touchy material & there will always be some cover up to do.
I use bondo because it sets up fast & is easy to work with - sands easy & accepts paint well.
It is also relatively lightweight
BONDO IS EXTREMELY MESSY & THE DUST CAN KILL - WORK WITH SMARTS & PROTECT YOURSELF.
Step 2: Initial trimming & such
I use a drill press armed with a grinding stone to remove all unnecessary material.
This is the first sanding step & believe me - you will get really sick of sanding with this project.
I will need to use a dremmel tool to finish the eye work & dental picks to clean out the grooves of any goofs.
I did these first 3 steps in about 4 hours.