I recently modded a Guitar Hero controller at the behest of fungus amungus. He's heading up the overview, and I'm going to show you how to create duplicates of your GH Controller keys in frosted clear plastic.
I'm going to review two types of molds using the same materials and principles. The first will be a simple block mold. The other will be the same block mold but it will include multiple castings. This is often called a gang mold.
You're going to need:
I'm going to review two types of molds using the same materials and principles. The first will be a simple block mold. The other will be the same block mold but it will include multiple castings. This is often called a gang mold.
You're going to need:
- RTV silicone. I will be using Smooth-On OMOO two part silicone molding compound. This is fairly easy and inexpensive to pick up. You can order it online or at some craft and plastics stores. Any RTV (or Room Temperature Vulcanizing) silicone will do. For this process the Polyester casting resin I will be using has some cure inhibition (meaning that it will remain sticky) against tin cure silicone (your standard inexpensive RTV). This means that to get good parts out of the mold, you will have to coat the mold in sealant before casting your parts, bake the parts after they're cured, or apply a clear sealant to the parts after they are molded.
- Latex Gloves
- Foamcore
- Stirring sticks
- A digital scale or graduated measuring cups
- Bondo car body filler. You can pick this up at most hardware stores and auto shops.
- Clear Polyester resin. Find it at a plastics store, or order it online. Sometimes craft stores will sell this as a way to make cutesy paperweights with flowers trapped in them, etc.
- MEKP catalyst. This will often come with your resin. You can also find it as fiberglass catalyst in most hardware stores.
- Polyester resin dye
- Respirator, ventilation system, or open well ventilated space to work in. Be mindful of your neighbors, as the polyester resin smells something awful, and will cause some people with sensitivities to feel ill.
- Hot glue
- A mold board. Any piece of smooth wood or plastic will do. Remember to seal the wood before casting on it, or else the mold will be difficult to remove.
- Disposable paint brushes
- Plenty of paper towels
- The touch
- The power
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Signing UpStep 1: Dismantle your controller
It's time to suck it up and take the screwdriver to this fancy bit of extruded dinosaurs. You must remove the main body panel before the neck will unfasten. Once you've opened the neck, take a small electronics screwdriver and carefully take out the circuit board (you are saving all the parts, right?) Remove the keys, and take their rubber bumpers off. The rubber bumpers will fit perfectly into the new keys once everything is done.
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Also, for sticky parts, I'd recommend low-heat baking of the part. It'll harden it up a bit-- just make sure you don't melt it.
I do have experience btw: http://www.scorehero.com/forum/viewtopic.php?t=72498&start=135
I will be putting the LEDs in a different guitar though.
You should look at two part castable urethanes like these: http://www.sculpt.com/catalog_98/CastingMaterials/URETHANES/clearurethane.htm
It's also going to be pretty important to make a good mold and either vac the mixture or cast it in a pressure pot to reduce the bubbles clouding up the mix.