Not sure if anybody hit on this, but I would not use the expanding foam. For not a lot more than you would pay for foam, just get some auto resin and bondo (or straight resin), mix them, and pour them into the hilt with the blade tip securely facing down to make sure the liquid settles in all the appropriate nooks and crannies.
You can get filler (the pink bondo stuff) that isn't bondo for pretty cheap, and the same goes for the resin. I wouldn't go to an auto parts store to buy it, at least not here in RI because it's less expensive at Lowe's or those weird discount stores like Benny's. The Rondo mix is really easy to work with (golf ball of bondo, 6 tablespoons of resin (or less, that's just the mixing measurement on the container), then add the bondo hardener and the 1/4 teaspoon (or less again) of the resin hardener, and pour it in. It sets quick, heats up, which makes it nice to remove the hot glue while it's curing, and you can sand out any imperfections as pull it out. You can also mold it to make more if you like, which will be more difficult with the foam.
I wouldn't use the foam for fear of blowing out your pep work, and you're right, it will feel flimsy because it is a porous material and may be more prone to breakage.
Hope this helps and sorry for the late response. Finally joined myself.
I was looking at 3D printing my helmet/armor and was looking at doing the same for the visor (separate from the helmet). How feasible would it be to mold the visor and then cast it in a clear resin? This question was asked previously, but nobody responded to it.
This would work for all of the various visor forms, especially some of the high-detail H4 visors (Warmaster, anyone?). Also, for some of the hex detailed visors, you could include the light inset of the hex on the visor.
It can be tinted before casting and a mirror tint added on the inside afterwards, too.
Would this be viable?
Okay so I was curious about casting, when I get to this stage what all will I need and how will I do it, because I've read a bunch of different ways to do it and non of them were very helpful. So if someone who knows what they are doing or has a better grasp of it then me could tell me, it would be greatly appreciated.
Browse youtube videos, try "Halo mold casting" or something and there are like three or four different tutorials. If you have specific questions, help is but a post away here.
I was checking the web for epoxy resins and there are hundreds out there...what do you guys use?
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